Production method of liquid crystal display device and liquid crystal display device

ABSTRACT

To provide a production method of a liquid crystal display device and a liquid crystal display device, in which generation of a joint line on a display screen is suppressed and yield can be improved even if a substrate is subjected to an alignment treatment by completing exposure for the substrate through several exposures in a liquid crystal display device including pixels each having two or more domains. The present invention is a production method of a production method of a liquid crystal display device, the liquid crystal display device including: a pair of opposed substrates; a liquid crystal layer formed between the pair of opposed substrates; and an alignment film arranged on a liquid crystal layer side surface of at least one of the pair of opposed substrates, and the liquid crystal display device having two or more regions which differ in alignment azimuth in a pixel, wherein the production method comprises an exposure step of exposing the alignment film in such a way that a substrate plane is divided into two or more exposure regions through a photomask in each exposure region, and in the exposure step, exposure is performed in such a way that adjacent two exposure regions have an overlapping exposure region where the adjacent two exposure regions partly overlap with each other, and the photomask has a halftone part corresponding to the overlapping exposure region.

TECHNICAL FIELD

This application is a divisional of U.S. patent application Ser. No.12/160,352 filed Jul. 9, 2008, now U.S. Pat. No. 7,872,718 which is theU.S. national phase of International Application No. PCT/JP 2007/051192,filed 25 Jan. 2007, which designated the U.S. and claims priority toJapan Application No. 2006-017755 filed 26 Jan. 2006, the entirecontents of each of which are hereby incorporated by reference.

The present invention relates to a method for producing a liquid crystaldisplay device and a liquid crystal display device. More specifically,the present invention relates to a method for producing a matrix liquidcrystal display device and a matrix liquid crystal display device, inwhich high display qualities can be obtained by forming two or moredomains in a pixel.

BACKGROUND ART

A liquid crystal display device has been widely used in a TV, a monitorfor personal computers, and the like, because it is a display devicewith low power consumption and it can be reduced in weight andthickness. However, according to the liquid crystal display device,light polarization is generally controlled by a tilt angle of a liquidmolecule in accordance with an applied voltage, and therefore the lighttransmittance depends on a viewing angle. Therefore, in the liquidcrystal display device, a contrast ratio is reduced and gradationreversal at the time of intermediate scale display, and the like, arecaused, depending on the viewing angle. Accordingly, such a commonliquid crystal display device has room for improvement in that theviewing angle characteristics are insufficient.

An alignment division technique in which alignment and tilt directionsof liquid crystal molecules are divided into two or more regions in onepixel has been developed. According to this technique, if a voltage isapplied to a liquid crystal layer, the liquid crystal molecules aretilted in different directions in the pixel, thereby improving theviewing angle characteristics of the liquid crystal display device. Therespective regions which differ in the alignment azimuth of the liquidcrystal molecules are each referred to as a domain. The alignmentdivision is also referred to as multi-domain.

With regard to the liquid crystal mode where the alignment division isperformed, examples of horizontal alignment mode include multi-domaintwist nematic (TN) mode, multi-domain electrically controlledbirefringence (ECB) mode, and multi-domain optically compensatedbirefringence (OCB) mode. In addition, multi-domain vertical alignment(MVA) mode, patterned vertical alignment (PVA) mode, and the like arementioned as a vertical alignment mode. Various modifications have beenmade to further improve the viewing angle in the liquid crystal displaydevices in various modes.

A rubbing method, a photo alignment method, and the like, may bementioned as such an alignment division method. With regard to therubbing method, an alignment division method of separating a rubbingregion from a non-rubbing region by patterning a resist has beenproposed. However, according to such a rubbing method, an alignment filmsurface is provided with an alignment treatment by being rubbed with acloth wound on a roller, which causes the following defects: damage onswitching elements by a fiber of the cloth, dusts such as rubbed scraps,or static electricity; characteristic shift; and characteristicdeterioration. In such a point, the rubbing method still has room forimprovement.

In contrast, the photo alignment method is an alignment method in whicha photo alignment film is used as a material for the alignment film, andthe photo alignment film is irradiated with a light beam such as UV,thereby being provided with an alignment regulating force. Accordingly,the alignment film can be provided with the alignment treatment in acontactless manner. Therefore, generation of soils, dusts, and the likeduring the alignment treatment can be suppressed. In addition, use of aphotomask at the time of exposure makes it possible to irradiate thealignment film with a light beam under conditions which vary dependingon a region in the alignment film surface. As a result, domains having adesired design can be easily formed.

As a conventional alignment division method using the photo alignmentmethod, the following method may be mentioned if one pixel is dividedinto two domains. A method in which a half region of the pixel issubjected with the first exposure using a photomask including atransmissive part and a shielding part corresponding to each pixel, andthen the photomask is shifted by about a half-pitch, and then the restregion of the pixel is subjected to the second exposure under conditionsdifferent from those in the first exposure. According to such a photoalignment method, each pixel can be easily divided into two or moredomains using the photomask. For example, the Patent Document 1discloses a technology of VAECB (vertical alignment ECB) mode in whichan alignment treatment is performed by the photo alignment method.

In addition, an increase in size, particularly in the liquid crystaldisplay device, has rapidly proceeded recently. Liquid crystal TVs in 40to 60-inch model have rapidly developed, although plasma TVsconventionally accounted for the greatest share of the devices in such asize. However, it is very difficult to perform the alignment division insuch a 60-inch liquid crystal display device by the above-mentionedconventional photo alignment method. The reason is given below. Anexposure device which can be installed in a factory is limited, andtherefore it is realistically impossible to install an exposure devicecapable of completing exposure for the 60-inch substrate by oneexposure. That is why it is impossible to complete exposure for theentire surface of the 60-inch substrate by one exposure. Accordingly,the exposure for the substrate needs to be completed through severalexposures, when a large liquid crystal display device is subjected tothe alignment division. Further, also if the alignment divisiontreatment is performed for a relatively small liquid crystal displaydevice in 20-inch model by the photo alignment method, the exposure forthe substrate might need to be completed through several exposures inthe case where the size of the exposure device needs to be decreased asmuch as possible. However, if the exposure for the substrate iscompleted through several exposures and thereby a liquid crystal displaydevice is prepared, a joint line between the exposure regions is clearlyobserved on the display screen.

Accordingly, if the liquid crystal display device is subjected to thealignment division by completing the exposure for the substrate throughseveral exposures, there is still room for improvement in thatgeneration of the joint line on the display screen is suppressed and theyield is improved.

-   [Patent Document 1]-   Japanese Kokai Publication No. 2001-281669

DISCLOSURE OF INVENTION

The present invention has been made in view of the above-mentioned stateof the art. The present invention provides a production method of aliquid crystal display device and a liquid crystal display device, inwhich generation of the joint line on the display screen is suppressedand the yield can be improved even if a substrate is subjected to thealignment division through several exposures in a liquid crystal displaydevice which includes two or more domains in each pixel.

The present inventors made various investigations on a production methodof a liquid crystal display device, in which the joint line is notobserved on the display screen even if the substrate is subjected to thealignment division through several exposures. The inventors noted anembodiment of the exposure which is performed several times for thesubstrate. The inventors found the following: even if irradiationconditions are different between a center region and a peripheral regionin the same exposure region, this difference is continuously changed inthe same plane and it is hardly observed by human eyes. However, it issubstantially impossible to irradiate the respective regions for whichthe exposure is separately performed on the substrate, under completelythe same conditions, even if the exposure is performed by an exposuredevice with the highest accuracy and using a photomask having a patternwith the highest accuracy. Even if the difference in the irradiationconditions between adjacent two exposure regions is small, the jointline is observed by human eyes because of the adjacent discontinuousconditions.

The present inventors made further investigations and found thefollowings: as the reason why the joint line is generated, a differencein irradiation amount between adjacent two exposure regions and adifference in proximity gap that is a distance between the mask and thesubstrate may be mentioned, and if polarized UV irradiation isperformed, a difference in the polarization axis, is mentioned, forexample. However, the main reason why the joint line is observed is adifference in alignment accuracy of a photomask between adjacent twoexposure regions. That is, even if the photomask is aligned with thehighest accuracy as much as possible on the exposure device,misalignment of about ±several micrometers is inevitable at the currenttechnical level. Further, even if the misalignment is within ±severalmicrometers, the joint line is surely observed by human eyes at theboundary between the adjacent two exposure regions.

Then, the inventors found that due to generation of this photomaskmisalignment, a position and a width of a dark line generated at theboundary between regions which differ in alignment azimuth in the pixel,that is, between domains, are discontinuously changed between the rightand left sides of the joint line, and as a result, the joint line isobserved. Further, the inventors found that the position and the widthof the dark line near the joint line can be continuously changed if theexposure for the substrate is completed through several exposures insuch a way that adjacent two exposure regions partly overlap with eachother using a photomask having a halftone part which corresponds to theoverlapping exposure region. As a result, the present inventors foundthat a production method of a liquid crystal display device and a liquidcrystal display device, in which the joint line is not observed on thedisplay screen even if the substrate is subjected to the alignmentdivision treatment by completing the exposure for the substrate throughseveral exposures. The above-mentioned problems have been admirablysolved, leading to completion of the present invention.

That is, the present invention is a production method of a liquidcrystal display device, the liquid crystal display device including: apair of opposed substrates; a liquid crystal layer formed between thepair of opposed substrates; and an alignment film arranged on a liquidcrystal layer side surface of at least one of the pair of opposedsubstrates, and the liquid crystal display device having two or moreregions which differ in alignment azimuth in a pixel, wherein theproduction method includes an exposure step of exposing the alignmentfilm in such a way that a substrate plane is divided into two or moreexposure regions through a photomask in each exposure region, and in theexposure step, exposure is performed in such a way that adjacent twoexposure regions have an overlapping exposure region where the adjacenttwo exposure regions partly overlap with each other, and the photomaskhas a halftone part corresponding to the overlapping exposure region.

The present invention also relates to a liquid crystal display deviceincluding a pair of opposed substrates, a liquid crystal layer formedbetween the pair of opposed substrates, and an alignment film arrangedon a liquid crystal layer side surface of at least one of the pair ofopposed substrates, and the liquid crystal display device having two ormore regions which differ in alignment azimuth in a pixel, wherein aposition and a width of a dark line generated between the two or moreregions which differ in alignment azimuth is continuously changedbetween adjacent two pixels.

The production method of the liquid crystal display device of thepresent invention is mentioned in more detail below.

The production method of the liquid crystal display device according tothe present invention includes an exposure step in which the alignmentfilm is exposed in such a way that a substrate plane is divided into twoor more exposure regions through a photomask in each of the two or moreexposure regions. Thus, the exposure for the substrate is completedthrough several exposures, and therefore even in a large liquid crystaldisplay device, the alignment division treatment can be performed forthe entire substrate using an exposure device in a normal size. Theembodiment of the division of the exposure region is not especiallylimited and it may be appropriately determined. Examples thereof includean embodiment in which the substrate is bisected, an embodiment in whichit is divided into three in a stripe pattern, a form in which it isdivided into four in a matrix pattern.

The above-mentioned alignment film is subjected to the alignmenttreatment by being exposed. Generally, the above-mentioned alignmentfilm is a photo alignment film formed of a material capable of changingan alignment azimuth of liquid crystals depending on a photo-irradiationdirection or a moving direction of a photo-irradiated region. The photoalignment film may exhibit an alignment regulating force by thephoto-irradiation. In the present description, the “alignment azimuth”means an azimuth shown by projecting a tilt direction of the liquidcrystal molecule included in the liquid crystal layer onto the substratesurface.

The above-mentioned photomask includes a transmissive part whichtransmits a light beam and a shielding part which shields a light beam.The transmissive part is not especially limited as long as it transmitsalight beam. The transmissive part may be formed using a transparentresin and the like, but preferably it is an opening where nothing isformed. A photomask prepared by forming a pattern of a metal film suchas a chromium film on a transparent substrate such as glass ispreferable as the photomask. The pattern of the photomask can beappropriately determined corresponding to a desired domain shape. It isparticularly preferable that the photomask has a repeated patternconsisting of a transmissive part and a shielding part. According tothis, the alignment treatment can be generally performed withefficiency, for pixels arrayed in a matrix pattern. The repeated patternis not especially limited, and a stripe pattern and a dot pattern arepreferable.

According to the exposure step in the present invention, the exposure isperformed in such a way that the adjacent two exposure regions partlyoverlap with each other. That is, the production method of the liquidcrystal display device of the present invention includes an exposurestep in which the alignment film is exposed in such a way that thesubstrate plane is divided into two or more exposure regions and theadjacent two exposure regions partly overlap with each other, throughthe photomask in each of the two or more exposure regions. Accordingly,in the present invention, generally, a part or the entire of thealignment film in the pixel near the joint line is exposed twice or morethrough two or more photomasks (hereinafter, also referred to as an“overlapping exposure”). The area of the overlapping exposure region(hereinafter, also referred to as an “overlapping region”) is notespecially limited. However, the position and the width of the dark linebetween the adjacent two exposure regions can be more smoothly connectedif the area is as large as possible. However, if the overlapping regionis too large, a larger photomask is needed, and therefore the exposuredevice needs to be larger. Accordingly, in order to suppress generationof the joint line and downsize the exposure device, it is preferablethat the area of the overlapping region is small enough for the jointline to be invisible. More specifically, the width of the overlappingregion is preferably about 10 to 80 mm, and more preferably about 30 to60 mm, and still more preferably about 40 to 50 mm. The totalirradiation amount in the overlapping exposure region (in the regionwhich is exposed twice through a plurality of photomasks) (hereinafter,also referred to as “total irradiation amount”) is preferably 50 to 200%and more preferably 70 to 150% relative to 100% of the irradiationamount in the non-overlapping exposure region, that is, the irradiationamount in the general region where the alignment film is exposed oncethrough one photomask. If the total irradiation amount is less than 50%,the total irradiation amount near the center of the overlapping regionis insufficient and the alignment film is not provided with a sufficientalignment regulating force. As a result, only such a position isobserved as an uneven position. If the total irradiation amount is morethan 200%, electrical characteristics might be deteriorated in theoverlapping region when a material with high sensitivity is used as thematerial for the alignment film. More specifically, residual DC, animage sticking phenomenon and the like might be generated, or a voltageholding ratio might be reduced.

The exposure method in the above-mentioned exposure step is notespecially limited, but simultaneous exposure and scanning exposure arepreferred. That is, it is preferable that the exposure step is performedwhile at least one of the substrate and a light source is moved(scanning exposure) or that the exposure step is performed with thesubstrate and a light source being fixed (simultaneous exposure). Thescanning exposure method is not especially limited as long as theexposure is performed while a position where a light beam is irradiatedon the substrate surface is moved. It is also called scanning exposure.As a specific embodiment of the scanning exposure, an embodiment inwhich while a light source and/or a substrate are/is moved, thesubstrate is irradiated with a light beam from the light source. Thescanning exposure is excellent in stability e.g., in an irradiationlight amount in the substrate plane, in comparison to the simultaneousexposure in which a light source and a region to be exposed are fixedand the region to be exposed is simultaneously exposed. Therefore,according to the scanning exposure, variation in characteristics of thealignment film, such as alignment azimuth and pretilt angle, can beeffectively suppressed. Further, a small exposure device is enough ifthe scanning exposure is employed. Therefore, device costs can bereduced. Also as the photomask, a small one is enough. Therefore, theaccuracy of the mask itself can be increased. If the light source ismoved in the scanning exposure, the light source and the photomask aregenerally integrally moved. The pretilt angle means an angle formed bythe alignment film surface and a longitudinal direction of the liquidcrystal molecule near the alignment film when no voltage is applied tothe liquid crystal layer (at OFF-state, during non-voltage application).In the scanning exposure, if panels which differ in a pitch of thetransmissive part are arranged in the scanning direction, the mask needsto be exchanged in accordance with the panels. However, according to thesimultaneous exposure, the different panels can be exposed at one timeusing a photomask which is previously provided with a plurality of panelpatterns. The simultaneous exposure is also called one-shot exposure.

If the above-mentioned scanning exposure is performed, it is preferablethat the pattern on the substrate is scanned by a camera for imagedetection and the like, and simultaneously, the moving direction of thesubstrate and/or the light source is controlled. As a result, if thesubstrate is distorted, the scanning exposure with high accuracy can beperformed along the pixel array. The scanned pattern on the substrate isnot especially limited, but a pattern which is periodically orcontinuously formed in the scanning direction is preferred. Among these,a bus line, a black matrix (BM) and the like, which are arranged on thesubstrate, are preferable.

In the present invention, it is preferable that in the above-mentionedexposure step, UV is made incident to a normal line of the substrateplane from an oblique direction, although depending on a material forthe alignment film to be exposed. As a result, the liquid crystal layercan be easily provided with a preferably pretilt angle in each liquidcrystal mode, and thereby a response speed of the liquid crystalmolecules can be improved. However, the light beam needs not to be madeincident to the substrate plane from an oblique direction, and it may bemade incident to the substrate plane from a substantially verticaldirection if appearance of the pretilt angle depends on the movingdirection of the photo-irradiated region, as in the photo alignmentmethod disclosed in “Photo-Rubbing Method: A Single-Exposure Method toStable Liquid-Crystal Pretilt Angle on Photo-Alignment Film”, M. Kimuraand three et al, IDW'04: proceedings of the 11th International DisplayWorkshops, IDW'04 Publication committee, 2004, and LCT2-1, p. 35-38.

It is preferable that the UV is polarized UV. If the alignment film isirradiated with anisotropic UV, anisotropic rearrangement or chemicalreaction of molecules in the alignment film can be easily induced.Accordingly, the alignment azimuth of the liquid molecules near thealignment film can be more uniformly controlled. The wavelength range ofthe UV can be appropriately determined depending on a material for theexposed alignment film.

The photomask in the present invention has a halftone part whichcorresponds to the overlapping exposure region. That is, theabove-mentioned photomask has a halftone part in a region correspondingto the overlapping exposure region. According to this, the joint linecan be effectively suppressed from being observed. As a result, theyield of the liquid crystal display device which is subjected to thealignment treatment by completing the exposure for the substrate throughseveral exposures can be improved. The reason why the joint line becomesinvisible is mentioned below. Accordingly, the halftone part ispreferably arranged on the end side (periphery side), more preferably atthe end (periphery) in the region where the transmissive part is formedof the photomask. In the present description, the halftone part means apart where a transmissive part having an aperture ratio smaller thanthat of a transmissive part in the region other than the halftone part(other than the overlapping exposure region) is arranged.

The aperture ratio means a proportion (percentage) of an area of therespective transmissive parts in the halftone part relative to anaverage area of the transmissive parts in the region other than thehalftone part. As mentioned herein, the photomask used in the presentinvention includes a halftone part at apart or the entire of the partcorresponding to the overlapping exposure region (overlapping region).

As an embodiment of the above-mentioned halftone part, an embodiment inwhich the halftone part includes transmissive parts with variousaperture ratios and the transmissive parts are arranged in descendingorder of the aperture ratios toward an end of the photomask ispreferable. In the present description, more specifically, the end ofthe photomask means an end of the photomask, which is positioned on theside opposed to the region corresponding to the region (general exposureregion) other than the overlapping exposure region. As a result, theposition and the width of the dark line between adjacent two exposureregions can be more smoothly connected. With regard to the change in theaperture ratio in the halftone part, (1) an embodiment in which a changein the aperture ratios is expressed as a linear function and anembodiment (2) in which a change in the aperture ratios is expressed asa trigonometric function. That is, it is preferable that in the halftonepart, a change in the aperture ratios is expressed as a linear function.Further, it is preferable that in the halftone part, a change in theaperture ratios is expressed as a trigonometric function. According tothe embodiment (1), generation of the discontinuous step can besuppressed in the halftone part. According to the embodiment (2),generation of the discontinuous step is suppressed, and additionally, adifferential coefficient of the change in the aperture ratio issubstantially zero between both ends of the halftone part. Therefore,the position and the width of the dark line between the overlappingregion and the other regions can be more smoothly connected. From such aviewpoint, the embodiment in which the aperture ratio is changed inaccordance with a linear function or the embodiment in which theaperture ratio is changed in accordance with a trigonometric function ispreferable as the embodiment in which the aperture ratio in the halftonepart is changed.

Preferable embodiments of the transmissive part in the halftone partinclude an embodiment (A) in which the transmissive parts have variouslengths, and the transmissive parts are arranged in descending order ofthe lengths toward an end of the photomask, an embodiment (B) in whichthe transmissive parts have various widths, and the transmissive partsare arranged in descending order of the widths toward an end of thephotomask, an embodiment (C) in which the transmissive parts include atransmissive part having a shape which is axial symmetry to a centerline which bisects a width of a transmissive part-arranged region, andan embodiment (D) in which the transmissive parts include a transmissivepart having a step shape. That is, it is preferable that in the halftonepart, the transmissive parts have various lengths, and the transmissiveparts are arranged in descending order of the lengths toward an end ofthe photomask; it is preferable that in the halftone part, thetransmissive parts have various widths, and the transmissive parts arearranged in descending order of the widths toward an end of thephotomask; it is preferable that in the halftone part, the transmissiveparts include a transmissive part having a shape which is axial symmetryto a center line which bisects a width of a transmissive part-arrangedregion; and it is preferable that in the halftone part, the transmissiveparts include a transmissive part having a step shape. The photomaskhaving the embodiment (A) is preferable as a mask for the scanningexposure. If such a photomask is used, the total irradiation amount inthe overlapping region can be easily controlled. The photomask havingthe embodiment (B) is preferable as a mask for the simultaneous exposureand the scanning exposure. If such a photomask is used, the position andthe width of the dark line can be continuously connected between theright and left sides of the joint line more effectively. The length ofthe transmissive part generally means, in a slit pattern, a length inthe long-side direction, or in a dot pattern, a length in the scanningdirection of the scanning exposure. In the slit pattern, the length ofthe transmissive part may be a length in the longitudinal direction.Further, the width of the transmissive part generally means, in a slitpattern, a length in the short-side direction, or in a dot pattern, alength in the direction substantially vertical to the scanning directionof the scanning exposure. In the slit pattern, the width of thetransmissive part may be a length in the direction substantiallyperpendicular to the longitudinal direction. According to the embodiment(C), the position and the width of the dark line can be continuouslyconnected between the right and left sides of the joint line moreeffectively. The transmissive part-arranged region means a region wherethe transmissive part is formed in the case where the aperture ratio inthe transmissive part is not decreased in the halftone part. That is, itmeans a region where the transmissive part is formed if it is assumedthat the halftone part also has an arrangement pattern of thetransmissive part, which the photomask in the region other than thehalftone part has. The width of the transmissive part-arranged region isa length of the transmissive part-arranged region in the same directionas the direction of the width of the transmissive part. Further, in thisembodiment, the transmissive part may not necessarily have a shape whichis strictly axial symmetry to the center line which strictly bisects thewidth of the transmissive part-arranged region. The transmissive partmay have a shape which is substantially axial symmetry to the centerline which substantially bisects the width of the transmissivepart-arranged region. The photomask in accordance with the embodiment(D) is preferably used as a mask for scanning exposure. If such aphotomask is used, a shift from 100% of the total irradiation amount inthe overlapping region can be suppressed to be a relatively small.

Further, according to the above-mentioned embodiment (B) in theabove-mentioned photomask, an embodiment (B-1) in which in thephotomask, a distance between center positions of two adjacenttransmissive parts is uniform and an embodiment (B-2) in which in thehalftone part, the transmissive parts include a transmissive part whichis divided from the center of a transmissive part-arranged region toboth sides, are preferable. According to the embodiment (B-1), in thesubstantially entire photomask, the distance between the centerpositions of two adjacent transmissive parts is not changed. Therefore,the position of the exposure region in the halftone part is morecontinuously changed, and the position and the width of the dark linecan be continuously changed on the right and left sides of the jointline. According to the photomask in the above-mentioned embodiment(B-1), the distance between the center positions of two adjacenttransmissive parts is not necessarily strictly uniform, and it may besubstantially uniform. Thus, the above-mentioned embodiment (B-1) may bean embodiment in which in the halftone part, the center of thetransmissive part is substantially the same as the center of thetransmissive part-arranged region. That is, the above-mentionedphotomask may have an embodiment in which in the halftone part, thecenter of the transmissive part is substantially the same as the centerof the transmissive part-arranged region. According to the embodiment(B-2), the transmissive part in the halftone part becomes thinner and itis divided from the center to both sides. If such a photomask is usedtogether with the photomask in accordance with the embodiment (B-1), anarea in the overlapping exposure region can be suppressed to be small.Therefore, deterioration of electrical characteristics, specifically,generation of residual DC and an image sticking phenomenon, and thelike, reduction in voltage holding ratio, and the like, can beeffectively suppressed. In accordance with the above-mentionedembodiment (B-2), the halftone part more preferably has an embodiment inwhich the transmissive part is substantially equally divided from thecenter of the transmissive part-arranged region to the both sides. Theabove-mentioned embodiments (A), (B), (C), (D), (B-1), and (B-2) may beappropriately applied to the photomask in combination, if needed. Therespective preferable embodiments in the above-mentioned productionmethod of the liquid crystal display device of the present invention maybe appropriately used in combination.

Other various conditions of the exposure in the present invention, suchas kind of the light source, the exposure amount, and the size of thephotomask may be appropriately determined depending on conditions forforming the alignment film such as a desired alignment azimuth and apretilt angle.

The reason why the joint line is observed and the reason why the jointline becomes invisible according to the present invention if thesubstrate is subjected to the alignment treatment by completing theexposure for the substrate through several exposures are mentionedbelow.

First, the reason why the joint line is observed is mentioned. If themask is misaligned when the exposure for the substrate is completedthrough several exposures, the position of the dark line becomesdifferent between adjacent two exposure regions, which results indifference in domain area ratio between the exposure regions.Accordingly, the optical characteristics are varied among the exposureregions. Therefore, particularly if the display screen is observed in anoblique direction, the luminance is discontinuously changed between theexposure regions. As a result, the boundary between the exposure regionsis observed as the joint line. If the width of the dark line isdifferent between adjacent two exposure regions, the luminance of thedomain is different between the exposure regions. Therefore, as in thecase where the position of the dark line is different, the luminance isdiscontinuously changed between the exposure regions. As a result, theboundary between the exposure regions is clearly observed as the jointline.

Then, the reason why the joint line becomes invisible is mentioned. Inthe halftone part of the photomask, if the aperture ratio iscontinuously changed, for example, by gradually thinning thetransmissive part, the position of the end of the transmissive part,that is, the position where the dark line is formed is graduallychanged. Further, if the scanning exposure is performed using aphotomask in which the aperture ratio is continuously changed, forexample, by gradually decreasing the transmissive part in the halftonepart, the total irradiation amount in the overlapping region isgradually changed, and therefore, the position where the dark line isformed is gradually changed. Accordingly, in the overlapping region, thedomain area ratio and the luminance between the exposure regions arecontinuously changed. Therefore, the joint line becomes invisible. Ifthe width of the dark line is different between the exposure regions, asin the case where the position of the dark line is different, the widthof the dark line is gradually changed in the overlapping region if thephotomask having the halftone part is used. Therefore, the joint linebecomes invisible. Thus, according to the production method of theliquid crystal display device of the present invention, even if themasks are misaligned in opposite directions between the right and leftsides of the joint line, the discontinuous dark lines at the joint linecan be connected due to use of the halftone part. Therefore, the jointline becomes hardly visible. Accordingly, according to the productionmethod of the present invention, even a very large liquid crystaldisplay device in 60-inch model can be produced with high yield.

In the present description, the dark line has a low luminance and it isgenerated on the display screen because the alignment azimuth and thepolarization axis direction of the polarizer are substantially the sameor substantially perpendicular to each other. Such a dark line isdifferent from a region where light from a backlight is shielded by ashielding body such as a bus line and a black matrix. The liquid crystalmolecules between different domains are tilted in different directions,although, during the voltage is applied, the liquid crystal moleculesare tilted in the same direction in the respective domains in themulti-domain pixel. Further, the liquid crystal molecule has acontinuous elastic body. Between the different domains, the liquidcrystal molecules are aligned to continuously connect the liquid crystalmolecules tilted in different directions to each other. Accordingly,between different domains where four-domain alignment is provided, thealignment azimuth of the liquid crystal molecules is substantially thesame as or substantially perpendicular to the polarization axisdirection of the polarizer generally included in the liquid crystaldisplay device when the liquid crystal display device is viewed infront. For the polarized light which transmits the region where theliquid crystal molecules are aligned in the direction substantially thesame as or substantially perpendicular to the polarization axisdirection of this polarizer, the retardation attributed to the liquidcrystal molecules is not generated. Accordingly, in this region, aftertransmitting a lower polarizer arranged on the backlight side, thepolarized light is not influenced by the liquid crystal layer, and thencut by an upper polarizer arranged on the display screen side. As aresult, the region where the liquid crystal molecules are aligned in thedirection substantially the same as or substantially perpendicular tothe polarization axis direction of the polarizer is observed as a darkline with a low luminance (corresponding to the dark line in the presentdescription).

As long as the production method of the liquid crystal display device ofthe present invention essentially includes the above-mentioned exposurestep, other steps are not especially limited.

The liquid crystal display device produced by the present inventionincludes a pair of opposed substrates; a liquid crystal layer formedbetween the pair of opposed substrates; and an alignment film arrangedon a liquid crystal layer side surface of at least one of the pair ofopposed substrates, and the liquid crystal display device has two ormore regions which differ in alignment azimuth in a pixel. With regardto the configuration of the liquid crystal display device produced bythe present invention, as long as the liquid crystal display deviceessentially includes common components such a multi-domain matrix liquidcrystal display device has, other components are not especially limited.In the present description, the two or more regions which differ inalignment azimuth mean a plurality of regions where the liquid crystalmolecules included in the liquid crystal layer are tilted in differentdirections when a voltage not lower than a specific threshold or avoltage lower than a specific threshold is applied to the liquid crystallayer (during a voltage application) or when no voltage is applied tothe liquid crystal layer (during non-voltage application). That is, itmeans a so-called domain. Thus, the two or more regions which differ inalignment azimuth preferably are a plurality of regions where the liquidcrystal molecules included in the liquid crystal layer are tilted indifferent directions when a voltage applied to the liquid crystal layeris changed.

Either one of the above-mentioned pair of opposed substrates ispreferably a TFT array substrate where thin film transistors(hereinafter, also referred to as a “TFT”) as a switching element andpixel electrodes are arranged in a matrix pattern. The other substrateof the above-mentioned pair of opposed substrates is a color filtersubstrate (hereinafter, also referred to as a “CF substrate”) includingcolor filters and common electrodes. Thus, the liquid crystal displaydevice produced by the present invention is preferably an active matrixliquid crystal display device, but it may be a passive matrix liquidcrystal display device. If the passive matrix liquid crystal displaydevice is produced by the present invention, a substrate includingsignal electrodes (column electrodes) which are arranged in a stripepattern and a substrate including scanning electrodes (row electrodes)which are arranged in a stripe pattern to be perpendicular to the signalelectrodes are used in combination, as the first and second substrates.In the present description, in an active matrix liquid crystal displaydevice, the pixel is determined by a pixel electrode and a commonelectrode facing the pixel electrode. Further, in a passive matrixliquid crystal element, the pixel is determined by an intersection ofthe signal electrodes and the scanning electrodes, arranged in a stripepattern.

According to the production method of the liquid crystal display devicein the present invention, the pattern of the photomask is appropriatelydetermined. Therefore, the liquid crystal display device produced by thepresent invention is not especially limited as long as it is in a liquidcrystal mode in which two or more domains are formed. The liquid crystaldisplay device in the present invention may have any multi-domain liquidcrystal mode, for example, horizontal alignment modes, such asmulti-domain TN mode, multi-domain STN (Super Twisted Nematic) mode,multi-domain ECB mode, and multi-domain OCB mode, and vertical alignmentmodes such as MVA mode and PVA mode. Among these, the multi-domain TNmode and the multi-domain VATN mode are preferable as the liquid crystalmode of the liquid crystal display device produced by the presentinvention. If a liquid crystal display device in the horizontalalignment mode is produced, it is preferable that the above-mentionedliquid crystal layer includes liquid crystal molecules with positivedielectric anisotropy. If a liquid crystal display device in thevertical alignment mode is produced, it is preferable that theabove-mentioned liquid crystal layer includes liquid crystal moleculeswith negative dielectric anisotropy.

As mentioned above, the present invention is also a production method ofthe liquid crystal display device including two or more regions whichdiffer in alignment azimuth in a pixel, wherein the method includes thestep of exposing the alignment film arranged on the substrate surfacethrough the photomask having the halftone part.

Further, the present invention is also a production method of a liquidcrystal display device including two or more regions which differ inalignment azimuth in a pixel, wherein the method includes: the firstexposure step of exposing the first exposure region of an alignment filmthrough the first photomask having the first halftone part; and thesecond exposure step of positioning the second photomask having thesecond halftone part in such a way that the second halftone part isarranged corresponding to the region which have been exposed through thefirst halftone part, and then exposing the second exposure region whichpartly overlaps with the first exposure region of the alignment filmthrough the second photomask.

Further, the present invention is a production method of a liquidcrystal display device, the liquid crystal display device including: apair of opposed substrates; a liquid crystal layer formed between thepair of opposed substrates; and an alignment film arranged on a liquidcrystal layer side surface of at least one of the pair of opposedsubstrates, and the liquid crystal display device having two or moreregions which differ in alignment azimuth in a pixel, wherein theproduction method includes the first exposure step of forming the firstexposure region by exposing the alignment film through the firstphotomask including a plurality of transmissive parts in the shieldingregion and the second exposure step of forming the second exposureregion by exposing the region partly overlapping with the first exposureregion of the alignment film through the second photomask including aplurality of transmissive parts in the shielding region, and the firstand second photomasks each include a halftone part in a regioncorresponding to the exposure region where the first exposure region andthe second exposure region overlap with each other (overlapping region),and in the second exposure step, at least part of the alignment film inthe pixel, which has been exposed through the halftone part of the firstphotomask in the first exposure step, is exposed through the secondphotomask.

The liquid crystal display device of the present invention is mentionedin more detail below.

The liquid crystal display device of the present invention includes apair of opposed substrates; a liquid crystal layer formed between thepair of opposed substrates; and an alignment film arranged on a liquidcrystal layer side surface of at least one of the pair of opposedsubstrates, and the liquid crystal display device has two or moreregions which differ in alignment azimuth in a pixel. Accordingly, theliquid crystal display device of the present invention is preferablyused in a multi-domain matrix liquid crystal display device. Further,such a liquid crystal display device has excellent viewing anglecharacteristics.

In the liquid crystal display device of the present invention, theposition and the width of the dark line generated between the regions(domains) which differ in alignment azimuth are continuously changedbetween adjacent two pixels. It is preferable that the above-mentioneddark line shows such a relationship in the entire display screen. In theliquid crystal display device where the alignment division isidentically provided, the position and the width of the dark linegenerally generated between the domains appear to be the same among thepixels. However, if the alignment division treatment is performed, theposition and width of the dark line are generally varied among thepixels because of limit of the accuracy of the treatment device,difference in the treatment conditions, and the like. In contrast,according to the liquid crystal display device of the present invention,even if the position and the width of the dark line are differentbetween the pixels, the position and the width of the dark line arecontinuously changed between adjacent two pixels, and therefore theluminance is continuously changed. As a result, the joint line on thedisplay screen becomes invisible. The method for producing the liquidcrystal display device of the present invention is not especiallylimited. However, the above-mentioned production method of the liquidcrystal display device according to the present invention can bepreferably used because the position and the width of the dark line arecontinuously changed. In the present description, the position of thedark line means a position where the luminance shows the minimum valuebetween different domains in the liquid crystal alignment region exceptfor a shielding body region (a region where the shielding body isarranged) in the liquid crystal display panel plane, for example, aregion on a bus line or a black matrix. The width of the dark line meansa distance between two points each showing the maximum luminance of 90%in the luminance cross-sectional curve in the direction substantiallyvertical to the dark line. The position and the width of the dark linecan be measured in the following manner, for example. A liquid crystaldisplay panel is placed under a polarization microscope includingpolarizers arranged in a Cross-Nicol state and a picture of each pixelin the panel is taken. Then, image processing is provided for each ofthe taken images.

In the present invention, if the position and the width of the dark lineare continuously changed in adjacent two pixels it is preferable that inadjacent two pixels, the changing amount of the position is less than 5μm and the changing amount of the width is 3 μm or less. It is morepreferable that the changing amount of the position is 2 μm or less andthe changing amount of the width is 3 μm or less. In this case, theluminance is more continuously changed in the liquid crystal displaydevice of the present invention. Therefore, the joint line on thedisplay screen can be more effectively suppressed from being observed.

Similarly to the substrates mentioned in the production method of theliquid crystal display device, a TFT array substrate and a CF substrateare preferable as the above-mentioned pair of opposed substrates, if theliquid crystal display device of the present invention is an activematrix liquid crystal display device. Further, if the liquid crystaldisplay device of the present invention is a passive matrix liquidcrystal display device, a substrate including signal electrodes and asubstrate including scanning electrodes are generally used incombination.

In the present invention, the above-mentioned alignment film is notespecially limited as long as it exhibits an alignment regulating force.A resin film for which alignment treatment is provided by rubbing, ionbeam irradiation or plasma irradiation; a photo alignment film for whichalignment treatment is provided by photo-irradiation; an inorganicsubstances such as obliquely deposited SiO, may be mentioned. Amongthese, it is preferable that the alignment film is a photo alignmentfilm. According to this, the liquid crystal display device of thepresent invention can be easily produced using the above-mentionedproduction method of the liquid crystal display device of the presentinvention. The material for the above-mentioned photo alignment film isnot especially limited as long as it is a material which generates analignment regulating force by photo-irradiation and which changes thealignment azimuth depending on the photo-irradiating direction or themoving direction of the photo-irradiated region. A resin including aphotosensitive group, and the like, may be mentioned. Among these, amaterial which causes at least one reaction or alignment, byphoto-irradiation, selected from the group consisting of crosslinkingreaction (including dimerization reaction), isomerization reaction, andphoto realignment is preferable. That is, it is preferable that thephoto alignment film causes at least one reaction or alignment, byphoto-irradiation, selected from the group consisting of crosslinkingreaction, isomerization reaction and photo realignment. According tothis, the variation in pretilt angle can be effectively suppressed incomparison to a photolysis photo alignment film material. The light beamused in the photo-irradiation is not especially limited, and polarizedUV is preferable. The alignment film material which causes crosslinkingreaction (including dimerization reaction), isomerization method, photorealignment, and the like is not especially limited, but polyimidecontaining a photosensitive group such as a 4-chalcone group (thefollowing formula (1)), a 4′-chalcone group (the following formula (2),a coumarin group (the following formula (3)), and a cinnamoyl group (thefollowing formula (4)) is preferable. A cinnamate group(C₆H₅—CH═CH—COO—) in which an oxygen atom is further bonded to acarbonyl group in the cinnamoyl group represented by the followingformula (4) has an advantage in that it can be easily synthesized.Accordingly, polyimide containing a cinnamate group is more preferableas the material for the photo alignment film. Further, if the alignmenttreatment is performed by ion beam irradiation or plasma irradiation, ametal mask is preferably used as the mask, for example.

The above-mentioned liquid crystal layer includes liquid crystalmolecules. The liquid crystal molecules are not especially limited. Theliquid crystal layer may contain a plurality of liquid crystalmaterials. It is preferable that the liquid crystal mode is a horizontalalignment mode or a vertical alignment mode. That is, in the presentinvention, it is preferable that the liquid crystal layer includesliquid crystal molecules with positive dielectric anisotropy; thealignment film is arranged on a liquid crystal layer side surface ofboth of the pair of opposed substrates, and the alignment film alignsthe liquid crystal molecules substantially horizontally to a surface ofthe alignment film when a voltage lower than a threshold is applied.Further, it is preferable that the liquid crystal layer includes liquidcrystal molecules with negative dielectric anisotropy; the alignmentfilm is arranged on a liquid crystal layer side surface of both of thepair of opposed substrates, and the alignment film aligns the liquidcrystal molecules substantially vertically to a surface of the alignmentfilm when a voltage lower than a threshold is applied.

In the above-mentioned liquid crystal display device in the horizontalalignment mode or the vertical alignment mode, the number of the domainmay be appropriately determined. It is preferable that two or more andfour or less of domains are formed. That is, in the above-mentionedliquid crystal display device in the horizontal alignment mode or thevertical alignment mode, it is preferable that two or more and four orless of regions (domains) which differ in alignment azimuth are formedin one pixel. It is more preferable that four regions which differ inalignment azimuth are formed in one pixel. According to this, theproduction steps can be suppressed from being complicated, andsimultaneously a liquid crystal display device excellent in viewingangle characteristics can be produced. If two domains are formed, on thedisplay screen, for example, the viewing angle in either one of thevertical and horizontal directions can be improved, but the viewingangle characteristics in the other direction can not be improved. Incontrast, if four domains are formed, the viewing angle in both of thevertical and horizontal directions can be improved. Simultaneously, theviewing angle characteristics in both directions can be uniform. Thatis, the viewing angle characteristics excellent in symmetry can beproduced. Therefore, a liquid crystal display device free from theviewing angle dependence can be produced. In the four-domain alignmentdivision, the arrangement of the four domains is not especially limited.A matrix pattern, a stripe pattern such as a horizontal stripe patternmay be mentioned, for example. Four or more domains may be formed, butthe production process becomes complicated and it takes longer toperform the alignment treatment. Further, it has been known that theviewing angle characteristics are not so different practically betweenthe four-domain alignment division and five or more-domain alignmentdivision.

In the present invention, it is preferable that the liquid crystal modeis a multi-domain TN mode or a multi-domain VATN mode. That is, in theabove-mentioned liquid crystal display device in the horizontalalignment mode or the vertical alignment mode, it is preferable that analignment azimuth of the liquid crystal molecules near the alignmentfilm arranged on one substrate is substantially perpendicular to analignment azimuth of the liquid crystal molecules near the alignmentfilm arranged on the other substrate when the pair of opposed substratesare viewed in plane. According to this, the viewing angle can beimproved in the liquid crystal display device of the present invention.The VATN (Vertical Alignment Twisted Nematic) mode is a mode in whichthe liquid crystal molecules are vertically aligned and form a twiststructure by using vertical alignment films whose alignment treatmentdirections are perpendicular to each other on the substrates. It ispreferable that the alignment azimuths of the liquid crystal moleculesnear the alignment film surface are the same as the alignment controlazimuths (alignment control direction) on the alignment film surfaces.

The liquid crystal display device mayor may not contain other componentsas long as it essentially includes such components. The configuration ofthe liquid crystal display device of the present invention is notespecially limited. For example, a part or the entire dark line may becovered with a shielding body (shielding member) such as a BM. A part ofthe dark line may be covered with the shielding member as long as theposition and the width of the dark line in the part not covered with theshielding body are continuously connected. In the case where the darkline is perfectly shielded with the shielding body in each pixel of theliquid crystal display device, the same operation and effects as in theliquid crystal display device of the present invention can be exhibitedif the position and the width of the shielding body are continuously andsmoothly connected. Thus, the liquid crystal display device of thepresent invention may be a liquid crystal display device including apair of opposed substrates, a liquid crystal layer formed between thepair of opposed substrates, and an alignment film arranged on a liquidcrystal layer side surface of at least one of the pair of opposedsubstrates, and the liquid crystal display device having two or moreregions which differ in alignment azimuth in a pixel, wherein theshielding body is arranged between the two or more regions which differin alignment azimuth, and a position and a width of the shielding bodyare continuously changed between adjacent two pixels. If the dark lineis perfectly shielded with the shielding body, it is preferable that theshielding body has a width larger than a width of the dark line in orderfor the dark line not to be across the display region (pixel opening).The preferable embodiments in the above-mentioned liquid crystal displaydevice of the present invention can be appropriately applied to such ashielding body-including liquid crystal display device according to thepresent invention.

Effect of the Invention

According to the production method of the liquid crystal display deviceof the present invention, generation of the joint line on the displayscreen is suppressed and the yield can be improved even if the substrateis subjected to the alignment treatment by completing the exposure forthe substrate through several exposures in a liquid crystal displaydevice including pixels each having two or more domains. Accordingly,even a large liquid crystal display device in 60-inch model can bestably produced, and the exposure device can be downsized. According tothe liquid crystal display device of the present invention, the positionand the width of the dark line are continuously changed. Therefore,generation of the joint line on the display screen can be suppressed.

BEST MODES FOR CARRYING OUT THE INVENTION

The present invention is mentioned in more detail below with referenceto Embodiments using drawings, but not limited to only theseEmbodiments.

Embodiment 1

With regard to a liquid crystal display device in accordance withEmbodiment 1 of the present invention, 1. Configuration of liquidcrystal display device, 2. Exposure method, 3. Screen joint shotprocess, 4. Photomask pattern, and 5. Verification test for sample panelare mentioned below.

1. Configuration of Liquid Crystal Display Device

The configuration of the liquid crystal display device in accordancewith Embodiment 1 of the present invention is mentioned, first. Theliquid crystal mode of the liquid crystal display device in accordancewith the present Embodiment is in four-domain VATN mode.

FIG. 2( a) is a cross-sectional view showing a configuration of onepixel in the liquid crystal display device in accordance withEmbodiment 1. As shown in FIG. 2( a), a liquid crystal display device101 includes a pair of opposed substrates, i.e., the first substrate 1(for example, a TFT array substrate) and the second substrate 2 (forexample, a CF substrate), and a liquid crystal layer 3 disposed betweenthe first substrate 1 and the second substrate 2. On the liquid crystallayer 3 side surface of the first substrate 1, a transparent electrode 4a for applying a driving voltage to the liquid crystal layer 3 and avertical alignment film 5 a on the transparent electrode 4 a are formed.Similarly, also on the liquid crystal layer 3 side surface of the secondsubstrate 2, a transparent electrode 4 b for applying a driving voltageto the liquid crystal layer 3 and a vertical alignment film 5 b on thetransparent electrode 4 b are formed. Further, on each of the firstsubstrate 1 and the second substrate 2, a retarder 25 and a polarizer 24are formed in this order from the substrate side. The retarder 25 maynot be arranged, but preferably, it is arranged in order to improve theviewing angle of the liquid crystal display device. The retarder 25 maybe arranged on only one substrate. Thus, the liquid crystal displaydevice 101 includes a so-called liquid crystal display panel. In thepresent Embodiment, the polarizer on the first substrate 1 side isreferred to as a lower polarizer 24 b and the polarizer on the secondsubstrate 2 side is referred to as an upper polarizer 24 a. The liquidcrystal layer 3 includes a nematic liquid crystal material with negativedielectric anisotropy (negative nematic liquid crystal material). Theliquid crystal layer 3 is arranged between a vertical alignment film 5 aformed on the liquid crystal layer 3 side surface of the first substrate1 and a vertical alignment film 5 b formed on the liquid crystal layer 3side surface of the second substrate 2. Liquid crystal molecules 3 a inthe liquid crystal layer 3 are aligned substantially vertically to thesurfaces of the vertical alignment films 5 a and 5 b when no drivingvoltage is applied to the liquid crystal layer 3 (during non-voltageapplication). In fact, the liquid crystal molecules 3 a are aligned tobe slightly tilted at about a several angle (pretilt angle) of 0.1° tothe surfaces of the vertical alignment films 5 a and 5 b. When a drivingvoltage is applied in the direction vertical to the liquid crystal layer3 surface and the driving voltage is increased to a threshold or more,the liquid crystal molecules 3 a are tilted in a certain direction inaccordance with this predetermined pretilt angle. When a sufficientdriving voltage is applied, the liquid crystal molecules 3 a in theliquid crystal layer 3 are aligned substantially parallel to thesurfaces of the first substrate 1 and the second substrate 2. Thedirection toward which the liquid crystal molecules 3 a are tilted isdetermined by the alignment control direction (alignment azimuth) on thevertical alignment film 5 a surface on the first substrate 1 and thealignment control direction (alignment azimuth) on the verticalalignment film 5 b surface on the second substrate 2. In the liquidcrystal display device 101 in accordance with the present Embodiment,the alignment azimuths on the surfaces of these vertical alignment films5 a and 5 b can be determined by subjecting only a desired part in eachpixel to UV treatment from a direction oblique to the substrate surfaceusing a photomask having a transmissive part which is designed tocorrespond to the pixel size and the pixel pitch.

FIG. 2( b) is a top view schematically showing the followings in onepixel: directions of the UV irradiation treatment provided for thevertical alignment film surfaces formed on the surfaces of the TFT arraysubstrate that is the first substrate and the CF substrate that is thesecond substrate; a pretilt angle direction toward which the liquidcrystal molecules on the alignment surfaces are finally tilted and analignment azimuth of the liquid crystal molecules when a voltage notlower than a threshold is applied; a polarization axis direction P ofthe upper polarizer 24 a; and a polarization axis direction Q of thelower polarizer 24 b. In FIG. 2( b), the liquid crystal molecule 3 aparticularly represents a tilt azimuth of a liquid crystal molecule nearthe middle layer (near the center of the cell) in the liquid crystallayer 3. The dotted arrow shows the direction of the UV irradiationprovided for the TFT array substrate that is the first substrate. Thesolid arrow shows the direction of the UV irradiation provided for theCF substrate that is the second substrate. In FIG. 2( b), the pixel 6 isdivided into eight regions, but the liquid crystal molecules are alignedin four alignment azimuths. Therefore, the liquid crystal display devicein the present Embodiment is a four-domain liquid crystal displaydevice. As shown in FIG. 2( b), according to the liquid crystal displaydevice 101 in the present Embodiment, the liquid crystal molecules 3 aare twist-aligned at 90 degrees during voltage application, and they arealigned in different tilt directions (specifically, the tilt angles aredifferent by substantially 90°) in accordance with the four domains.That is, the liquid crystal display device 101 in the present Embodimenthas a four-domain VATN mode as a liquid crystal mode. The liquid crystaldisplay device 101 in the present Embodiment includes orthogonalpolarizers in which the polarization axis direction P of the upperpolarizer and the polarization axis direction Q of the lower polarizerare perpendicular to each other when the substrates are viewed in plane.Accordingly, when a voltage is applied, light incident from the lowerpolarizer 24 b is polarized in the polarization axis direction P andthen rotated by 90° along the twist of the liquid crystal molecules 3 ain the liquid crystal layer 3, and then turned into polarization lightin the polarization axis direction Q to be emitted from the upperpolarizer 24 a. In the present description, the polarization axis meansan absorption axis. The polarization axis direction P of the upperpolarizer 24 a and the polarization axis direction Q of the lowerpolarizer 24 b are not especially limited to the above-mentioneddirections, and may be appropriately determined. It is preferable thatwhen the substrates are viewed in plane, an angle made by thepolarization axis direction P of the upper polarizer 24 and thepolarization axis direction Q of the lower polarizer 24 b is 90°. Thatis, it is preferable that the Cross-Nicol relationship is satisfied.

In the liquid crystal display device 101 in the present Embodiment, thetilt angles of the liquid crystal molecules 3 a in the respectivedomains make a substantially 90° with each other if the substrates areviewed in plane when a voltage is applied, as mentioned above.Accordingly, at the boundary between different domains, the liquidcrystal molecules 3 a are aligned in such a way that the liquid crystalmolecules 3 a tilted in different directions are continuously connected,that is, the substantially 90° is bisected. As shown in FIG. 2( b), thedirection toward which the liquid crystal molecules 3 a near the middlelayer of the liquid crystal layer 3 is different from the polarizationaxis direction P of the upper polarizer 24 a and the polarization axisdirection Q of the lower polarizer 24 b by substantially 45°. As aresult, the alignment azimuth of the liquid crystal molecules at theboundary between different domains is substantially the same as orsubstantially perpendicular to the polarization axis direction P of theupper polarizer 24 a or the polarization axis direction Q of the lowerpolarizer 24 b. Accordingly, at the boundary between different domains,the retardation attributed to the liquid crystal molecules 3 a is notprovided for the polarized light. That is, after transmitting the lowerpolarizer 24 b, the polarized light is not influenced by the liquidcrystal layer 3. Therefore, the polarized light which has transmittedthe lower polarizer 24 b can not transmit the upper polarizer 24 a.Therefore, a dark line with a low luminance is generated at the boundarybetween different domains.

The four-domain VATN mode has an advantage in terms of the alignmentdivision that the number of the device and the time taken for thealignment treatment (tact time) can be reduced because two irradiationsare performed for one side of each substrate, that is, totally, fourirradiations are performed for the substrates, thereby forming fourdomains where the liquid crystal molecules 3 a are aligned in differentazimuths in the pixel. To divide the pixel into four domains is apreferable embodiment in order to improve the viewing angle of theliquid crystal display device. If the pixel is divided into two domains,the viewing angle in either one of the vertical or horizontal directionscan be improved, but the viewing angle characteristics in the otherdirection can not be improved. However, if the pixel is divided intofour domains, the viewing angle in both of the vertical and horizontaldirections can be improved. Simultaneously, the viewing anglecharacteristics in both directions can be uniform. That is, the viewingangle characteristics excellent in symmetry can be obtained. Therefore,a liquid crystal display device free from the viewing angle dependencecan be produced. Five or more domains may be formed, which is notpreferable because the processes become complicated and the treatmenttime becomes longer. Further, it has been known that the viewing anglecharacteristics are not so different practically between four domainsand five or more domains.

According to the present Embodiment, the vertical alignment liquidcrystal display device is mentioned. However, the present Embodiment maybe similarly applied to a horizontal alignment liquid crystal displaydevice. In a horizontal alignment liquid crystal display device, theliquid crystal layer 3 includes a nematic liquid crystal material withpositive dielectric anisotropy (positive nematic liquid crystalmaterial). Further, the liquid crystal layer 3 is arranged between ahorizontal alignment film 7 a formed on the liquid crystal layer 3 sideof the first substrate 1 and a horizontal alignment film 7 b formed onthe liquid crystal layer 3 side of the second substrate 2, instead ofthe vertical alignment films 5 a and 5 b shown in FIG. 2( a).

2. Exposure Method

An exposure method used when the four-domain VATN liquid crystal displaydevice in the present Embodiment is produced is mentioned with referenceto FIGS. 3 and 4. First, a photomask 200 a is aligned and fixed at adesired position of the TFT array substrate by scanning an alignmentmarker formed on the substrate. The photomask includes transmissiveparts and shielding parts formed in a stripe pattern. Each width of thetransmissive part and the shielding part is half the pixel pitch. Thereis a distance (proximity gap 8) between the photomask 200 a and the TFTarray substrate 1, as shown in FIG. 4( d). This distance is formed toprevent a photomask from sagging under its own weight and contacting thesubstrate surface when the photomask is large. As shown in FIGS. 3( a)and 4(a), the substrate is irradiated with polarized UV from an obliquedirection along the direction A. Hereinafter, this irradiation isreferred to as A shot. FIG. 4( c) is a perspective view schematicallyshowing an oblique irradiation direction of polarized UV 9. On the TFTarray substrate and the CF substrate, as shown in FIG. 4( d), analignment film material (photo alignment film material) which reactswith the polarized UV, thereby tilting liquid crystal molecules 3 a nearthe alignment films (not shown) at a pretilt angle 10 in the UVirradiation direction is arranged. After the A shot, as shown in FIG. 4(a), for example, the photomask 200 a is parallel-moved in the xdirection by a ½ pitch of the pixel pitch Px. Then, the substrate isirradiated with polarized UV along the B direction. Hereinafter, thisirradiation is referred to as B shot. Then, as shown in FIGS. 3( b) and4(b), a photomask 200 b for the CF substrate is similarly aligned andthe A shot is provided for the substrate. After the A shot, for example,the photomask 200 b is parallel-moved in the y direction perpendicularto the x direction by a ¼ pitch of the pixel pitch Py. Then, the B shotis provided for the substrate. Then, the cell is prepared in commonprocedures and then the liquid crystal material is injected to completethe panel. Then, as shown in FIG. 2( b), a four-domain liquid crystaldisplay panel in which the liquid crystal molecules are aligned in fouralignment azimuths when a voltage not lower than a threshold is applied,can be produced. Finally, module-producing steps including adriver-loading step, a back light-fixing step, and the like areperformed to complete the liquid crystal display device in the presentEmbodiment.

According to the present Embodiment, when the exposure is performed todivide the pixel into four domains, the photomask 200 a in which astripe pattern having a ½ pitch of the pixel pitch in the x direction isformed is used to expose the TFT array substrate and the photomask 200 bin which a stripe pattern having a ¼ pitch of the pixel pitch in the ydirection is used for the CF substrate. However, the patterns are notlimited thereto and may be appropriately determined depending on thelayout or size of the pixel, resolution of the panel, and the like.Further, in the present Embodiment, the four domains are arranged in amatrix pattern, but the pattern is not especially limited. The fourdomains may be arranged in a stripe pattern such as a horizontal stripepattern, and others. It is preferable that each boundary between thedomains is arranged in the direction substantially parallel to theboundary between the pixels, as in the present Embodiment.

Materials usable in the present Embodiment and conditions of productionprocesses applicable for the present Embodiment are mentioned below. Thematerials and the conditions usable in the present Embodiment are notespecially limited to those mentioned below. In the present Embodiment,polarized light may not necessarily be used, and non-polarized light(extinction ratio=1:1) may be used. It may be appropriately determineddepending on the material for the alignment film, production processes,and the like.

Liquid crystal material: Δn (birefringence)=0.06 to 0.14, Δ∈ (dielectricanisotropy)=−2.0 to −8.0, Tni (nematic-anisotropic phase transitiontemperature)=60 to 110°

Pretilt angle: 85 to 89.9°

Cell thickness: 2 to 5 μm

Irradiation amount: 0.01 to 5 J/cm²

Proximity gap: 10 to 250 μm

Light source: a low pressure mercury lamp, a high pressure mercury lamp,a heavy hydrogen lamp, a metal halide lamp, an argon resonance lamp, axenon lamp, an excimer laser.

Extinction ratio of polarized UV (polarization degree): 1:1 to 60:1

Direction of UV irradiation: a direction at 0 to 60° relative to thenormal direction of the substrate surface

3. Screen Joint Shot Process

The method of dividing the pixel into four domains is mentioned above.If the substrate is small, as shown in FIG. 4, the exposure treatment iscompleted after two irradiations (the A and B shots) for the TFT arraysubstrate and two irradiations (the A and B shots) for the CF substrate,i.e., totally, four irradiations. However, if the substrate is large,for example, if a substrate is used in a current large liquid crystal TVin 60 or larger-inch model, the entire region of such a large substratecan not be exposed in one shot. Accordingly, in such a case, a processof completing the exposure for the substrate in several shots(divisional shot process, screen joint shot process) is essentiallyneeded. The screen joint shot process is mentioned with reference toFIG. 1 that is a conceptual view showing the screen joint shot processin the present Embodiment.

As shown in the left figure of FIG. 1( a), the left side of thealignment film 5 on a large substrate 13 that is the first or secondsubstrate is irradiated with polarized UV 9 twice (the A shot and the Bshot). Hereinafter, these shots are referred to as the 1st shot.Successively, as shown in the right figure of FIG. 1( a), the substrate,or the light source and the photomask is/are parallel-moved, and thealignment is fixed. Then, the right side of the alignment film 5 on thelarge substrate 13 is irradiated with the polarized UV 9 twice (the Aand B shots). Hereinafter, these shots are referred to as the 2nd shot.At this time, only a specific region near the screen joint part of thelarge substrate 13 is redundantly exposed (overlapping exposure) usingthe photomask 200. That is, as shown in FIG. 1( b), the large substrate13 is exposed twice in the region where the exposure is redundantlyperformed (overlapping region 11). The photomask 200 basically has astripe pattern for dividing each pixel into four domains, for example, apattern including transmissive parts S and shielding parts L each havinga width of ½ or ¼ of the pixel pitch, as shown in FIG. 4. As shown inFIG. 1( c), the photomask 200 has a halftone part 12 in the overlappingregion 11. In this halftone part 12, the transmissive part (S) in astripe pattern has a specific halftone pattern (graduation pattern), andan aperture ratio of the transmissive part (S) is gradually changed. Theway of forming the halftone pattern is mentioned below in more detail.It is preferable that the halftone pattern is formed as smoothly aspossible, so as not to generate a discontinuous step.

In the present Embodiment, using the photomask 200 having the halftonepart, the screen joint shot process in which the overlapping exposure isperformed is performed. If the screen joint shot is performed using thephotomask without the halftone part, the boundary of the joint (jointline) is clearly observed regardless whether or not the overlappingexposure is performed. The reason of this is mentioned below. It isimpossible to irradiate the regions in the vertical direction or theregions in the horizontal direction, which are exposed in differentshots under completely the same conditions even if the accuracy of thedevice, the photomask, the alignment, and the like is minimized as muchas possible. Further, even if the difference in the irradiationconditions between the regions exposed in different shots is small, thediscontinuous conditions are adjacent between the regions exposed indifferent shots. If the center part and the peripheral part in the sameexposure region are exposed under different irradiation conditions, thisdifference is often continuously changed in the same exposure region,and therefore the joint line is hardly observed. Thus, the main objectof the present invention is to provide a production method of a liquidcrystal display device and a liquid crystal display device, in whichgeneration of the joint line, as the main problem in the screen jointshot, is effectively suppressed.

FIG. 1 shows the case where two shots, i.e., the 1st and 2nd shots, areperformed for each substrate. However, the number of times of the screenjoint shot (the number of joints) is not limited to two. If the numberof joints is increased, the mask, the light source, and the device canbe downsized, but the joint line is increased. Therefore, the joint linebecomes observed, which often results in defects. If the number ofjoints is suppressed to the minimum, the mask, the light source, and thedevice, each in a huge size, are needed. Therefore, problems such asincrease in space for the device in a factory, increase in costs of thedevice, uneven pattern of the huge mask, are caused. Accordingly, it ispreferable that the number of joints is appropriately determineddepending on the size of the substrate, the layout of the factory, andthe like. Table 1 shows a difference between the above-mentioned shotsperformed for dividing the pixel into four domains (the A and B shots)and the screen joint shot (the respective shots such as the 1st shot andthe 2nd shot).

TABLE 1 Each screen joint shot (1st, 2nd, . . . ) TFT array A shot Bshot substrate CF substrate A shot B shot

The present Embodiment essentially needs the screen joint shot processbecause, as shown in FIG. 5, a region 14 (thick line part) exposed inone shot is smaller than the contour of the large substrate 13 (narrowline part). The number of times of the exposure for the TFT arraysubstrate is totally four, because two shots, i.e., the A and B shot,are performed in each of the 1st shot and the 2nd shot to divide eachpixel into four domains. Similarly in the CF substrate, the number oftimes of the exposure is totally four because two shots, i.e., the A andB shots, are performed in each of the 1st shot and the 2nd shot todivide each pixel into four domains. Accordingly, the total number oftimes of the exposure for one panel is eight.

The photomask 200 used in the present Embodiment is slightly larger thanthe half of the substrate, and it has halftone parts 12 on opposed tworegions on the both sides, respectively, as shown in FIG. 6. FIG. 6( a)is a top view schematically showing the 1st and 2nd shots for the TFTarray substrate 1 and an enlarged schematic view showing a pattern ofthe halftone part 12. FIG. 6( b) is a top view schematically showing the1st and 2nd shots for the CF substrate 2 and an enlarged schematic viewshowing a pattern of the halftone part 12. As shown in FIG. 6, if thescreen joint shot process is performed, a liquid crystal display devicein which the joint line is not observed can be produced. In this case,only one of the two halftone parts 12 formed in the photomask 200 isarranged near the joint line and the other one is arranged outside thesubstrate. The aperture ratio of the halftone part 12 is changed in alinear pattern in every three pixels (every RGB unit). With regard tothe pattern of the halftone part 12, a pattern in which the width of theslit pattern is gradually decreased toward the end of the photomask isused for the TFT array substrate 1 and the CF substrate 2, as shown inthe enlarged schematic views in FIG. 6. Further, as shown in FIG. 7, ifthe screen joint shot is performed using a photomask 200 which is halfthe substrate and has no halftone part, the center line of the substrateis clearly observed as the joint line regardless of whether or not theoverlapping exposure is performed. Thus, it is found that theoverlapping exposure needs to be performed using the photomask havingthe halftone part in the screen joint shot process.

4. Photomask Pattern

A preferable way of forming the pattern of the halftone part in thephotomask is mentioned in more detail below with reference to FIGS. 8 to10 and 27. FIG. 8 shows a photomask pattern without the halftone part,which is used when the substrate is not redundantly exposed. FIG. 9shows a photomask pattern with the halftone part, which is used when thesubstrate is redundantly exposed. FIG. 10 shows another photomaskpattern with the halftone part, which is used when the substrate isredundantly exposed. FIG. 27 shows another pattern with the halftonepart, which is used when the substrate is redundantly exposed. Thephotomasks having the patterns shown in FIGS. 9, 10, and 27 are those ofthe present invention. The photomask having the pattern in FIG. 8 is acomparative photomask in which the joint line will be observed.

First, the case where the substrate is not redundantly exposed using thephotomask without the halftone part is mentioned with reference to FIG.8. FIG. 8( a) shows patterns of the respective photomasks and thearrangement thereof. FIG. 8( b) shows a region to be exposed when theexposure is performed using the photomasks shown in FIG. 8( a). FIG. 8(a) shows an arrangement of the photomasks when they are accuratelypositioned without misalignment. The upper two lines show the A shot (Ain the drawings) and the B shot (B in the drawings) in the 1st shot (the1st in the drawings). The lower two lines show the A shot (A in thedrawings) and the B shot (B in the drawings) in the 2nd shot (the 2nd inthe drawings). In FIG. 8( b), the upper line shows a region which isactually exposed when the photomasks are accurately positioned. Theupper two lines in this upper line shows an exposure region in the Ashot and an exposure region in the B shot in the 1st shot. The lower twolines in this upper line shows an exposure region in the A shot and anexposure region in the B shot in the 2nd shot. The exposure region inthe A shot is shown with an oblique line and the exposure region in theB shot is shown with a lattice pattern. Thus, if the photomasks areaccurately positioned and the exposure for the right and the exposurefor the left are identically performed under the same conditions, theposition and the width at the boundary between the A shot and the Bshot, that is, the position and the width of the dark line, arecompletely the same between the right and left region of the joint lineand therefore, the joint line is not observed. However, it is impossibleto irradiate the right and left regions of the joint line undercompletely the same conditions, in fact. Therefore, if these photomasksare used, the joint line is observed.

The case where the photomasks in FIG. 8 are misaligned is mentioned.According to the alignment accuracy of the device, misalignment within±several micrometers is inevitable when a large substrate and a largemask are used. The lower line in FIG. 8( b) shows exposure regions whenthe photomasks are misaligned. The arrow shows a position where the darkline is generated. Specifically, the lower line in FIG. 8( b) shows acase where the photomask is misaligned to the right by about 5 μm in the1st shot, and the photomask is misaligned to the left by about 5 μm inthe 2nd shot, for example. The dark line generated in the verticaldirection in one pixel is generated at the boundary between the A shotand the B shot. Therefore, the position of the dark line is shifted tothe right by about 5 μm on the left side of the joint line and theposition of the dark line is shifted to the left by about 5 μm on theright side of the joint line. As a result, the position of the dark lineis rapidly changed between the right and left sides of the joint line.Therefore, particularly if the screen is observed from an obliquedirection, a difference in luminance is clearly observed between theright and left sides of the joint, and the joint line is observed. Thereason why the difference in luminance between the right and left sidesof the joint line is generated is mentioned below. The present inventorsfound that it is because an area ratio of the four domains in one pixelis different between the right and left sides of the joint line. As thereason why the joint line is observed, other reasons may be mentioned inaddition to the misalignment of the photomask. The present inventorsfound that this misalignment due to error of the alignment accuracy isthe main reason. Therefore, the main object of the present inventors isto design a photomask pattern which can connect the position and thewidth of the dark line continuously and smoothly between the right andleft sides of the joint line even if the photomask is misaligned.

FIG. 9 shows a photomask pattern which the present inventors though as apreferable one after repeated trial and error. This photomask has ahalftone part shown in FIG. 9 in the overlapping region near the jointline. In the halftone part, the transmissive parts S are arranged indescending order of the widths toward the end of the photomask. Theaperture ratio in each transmissive part is shown above the each line,in FIG. 9( a). In this halftone part, the transmissive parts S include atransmissive part having a shape which is axial symmetry to a centerline which bisects a width of a transmissive part-arranged region isarranged. Further, according to this halftone part, the transmissiveparts S are arranged with a substantially uniform distance betweenadjacent two of them. Further, the aperture ratio in the transmissivepart is changed at a rate as small as possible also between the valuesshown in FIG. 9. The aperture ratio is changed in accordance with alinear function. In the halftone part, the width of the transmissivepart S is decreased by 1 μm from the right and left sides, i.e., totally2 μm. The aperture ratio in the transmissive part S in the halftone partis continuously changed up to 0% (perfect shielding). The reason why thewidth of the transmissive part S is decreased by about 1 μm from eachend is because the minimum lithography line width of the photomask issubstantially 1 μm, generally. The reason why it was expected that tochange the aperture ratio in the transmissive part S would be effectivefor eliminating the joint line is mentioned below. Similarly in thelower line in FIG. 8( b), the lower line in FIG. 9( b) shows a casewhere in the exposures, the photomask is misaligned to the right byabout 5 μm in the 1st shot, and the photomask is misaligned to the leftby about 5 μm in the 2nd shot. The actually exposed region in the A shotis shown with an oblique line and that in the B shot is shown with alattice pattern. In this case, the position of the dark line in the mostleft pixel is shifted to the right by about 5 μm and the position of thedark line in the most right pixel is shifted to the left by about 5 μm.If the pixels are observed from left to right, the region which isexposed in the B shot in the 2nd shot becomes closer to the dark line(generated at the boundary between the A shot and the B shot in the 1stshot) gradually. Further, in the fourth pixel from the left in FIG. 9(b), the left end of the region which is exposed in the B shot in the 2ndshot just correspond to the dark line (generated at the boundary betweenthe A shot and the B shot in the 1st shot). Further, if the pixels arefurther observed in the right direction, the left end of the regionwhich is exposed in the B shot in the 2nd shot is across the boundarybetween the A shot and the B shot in the 1st shot. On the right side ofthe center in the overlapping region, the exposure region exceeds to theleft by about 5 μm. The present inventors found after variousinvestigations that if the photo alignment film is irradiated in opposedtwo directions, the direction of the latter irradiation is givenpriority, and therefore the liquid crystal molecules are aligned in thelatter irradiation direction. Accordingly, in the right direction of thecenter of the overlapping region, the 2nd shot is given priority andtherefore, the dark line generated in the vertical direction in thepixel is generated at the boundary between the A shot and the B shot.Therefore, it can be expected from FIG. 9( b) that the position of thedark line generated in the vertical direction is shifted to the left byabout 5 μm. As a result, in the pixels from the most left to the fourthfrom the left, the position of the dark line is shifted to the right byabout 5 μm. In the pixels from the sixth from the left to the mostright, the position of the dark line is shifted to the left by about 5μm. In the fifth pixel from the left, the dark line is generated at theboundary between the A shot and the B shot in the 2nd shot, and theposition of the dark line is shifted to the left. However, the width ofthe transmissive part S in the 2nd shot is decreased, and therefore theshift of the position of the dark line is not as large as 5 μm.Accordingly, the screen joint shot is performed using the photomaskshown in FIG. 9, and thereby the position of the dark line can becontinuously connected between the right and left sides of the jointline.

FIG. 10 shows another photomask pattern which is expected to be apreferable one. This photomask also has a halftone part in theoverlapping region near the joint line, as shown in FIG. 10. However, inthe halftone part of the photomask for the 1st shot, the transmissivepart S is divided from the center to both sides, that is, it is dividedinto two having an equal width from the center of the transmissivepart-arranged region to the right and left sides, and the width of thetransmissive part S is gradually decreased. As a result, as in thephotomask in FIG. 9, the position of the dark line can be continuouslyconnected between the right and left sides of the joint line. Further,if the overlapping exposure region (the region to be exposed twice) ismore reduced (the region which corresponds to the maximum difference ofthe position between the 1st and 2nd shots is exposed twice), themaximum irradiation amount can be reduced. The maximum irradiationamount is the maximum total value of the aperture ratio in thetransmissive part in the photomask for the 1st shot and the apertureratio in the transmissive part in the photomask for the 2nd shotcorresponding to the transmissive part in the photomask for the 1stshot. Specifically, according to the photomask shown in FIG. 10, in thepixels from the fourth to the seventh from the left, a total apertureratio in the transmissive part of the photomask in the 1st shot and inthe transmissive part of the photomask in the 2nd shot is 140% in eachpixel. According to the photomask shown in FIG. 10, the maximumirradiation amount can be reduced to 140%. Similarly in FIG. 9, theaperture ratio in each transmissive part is shown above the each line,in FIG. 10( a). Further, the aperture ratio in the transmissive part ischanged at a rate as small as possible also between the values shown inFIG. 10. The aperture ratio is changed in accordance with a linearfunction. In the halftone part of the photomask used for the 1st shot,the width of the transmissive part S is gradually decreased toward theend of the photomask by 1 μm that is the minimum lithography line fromthe center to the right and left sides, i.e., totally 2 μm. The apertureratio in the transmissive part S in the halftone part is continuouslychanged up to 0% (perfect shielding). That is, in the halftone part ofthe photomask in the 1st shot, each transmissive part S is divided fromthe center of the transmissive part-arranged region to the right andleft sides, and the width of the divided transmissive part is graduallydecreased toward the end of the photomask by 1 μm from the center sideof the transmissive part-arranged region. In the halftone part of thephotomask in the 2nd shot, the width of the transmissive part S isgradually decreased toward the end of the photomask by 1 μm from theright and left ends, similarly in FIG. 9.

FIG. 27 shows another photomask pattern which is expected to be apreferable one. As shown in FIG. 27, this photomask has a pattern inwhich the length of the transmissive part is gradually decreased in theregion at the end of the halftone part, in addition to the same patternas in FIG. 10. According to this, the aperture ratio at the end of thehalftone part can be more smoothly changed. Therefore, similarly to thephotomasks in FIGS. 9 and 10, the position of the dark line can be morecontinuously connected between the right and left sides of the jointline. Near the end of the halftone part, the overlapping exposure region(the region to be exposed twice) can be further reduced. Similarly toFIGS. 9 and 10, the aperture ratio in each transmissive part is shownabove the each line, in FIG. 27( a). Further, the aperture ratio in thetransmissive part is changed at a rate as small as possible also betweenthe values shown in FIG. 27. The aperture ratio is changed in accordancewith a linear function in the region where the length of thetransmissive part is not decreased, and the aperture ratio is changed by½ times in accordance with an exponential function in the region wherethe length of the transmissive part is decreased. In the region wherethe length of the transmissive part is decreased, the length of thetransmissive part may be changed in accordance with a trigonometricfunction. The halftone pattern in the region where the length of thetransmissive part is not decreased is formed in the same manner as inthe photomask in FIG. 10.

The aperture ratio in the transmissive part in the halftone part of thephotomask in FIGS. 9 and 10 may be changed in accordance with atrigonometric function. According to this, the differential coefficientof change in the aperture ratio at both ends of the halftone part can besubstantially zero, and the position of the dark line can be moresmoothly connected in comparison to the linear function. As a result,defects attributed to that the joint line is observed can be moresuppressed from being observed. The used trigonometric function is notespecially limited, but, for example, the formulae (1) to (4) mentionedin Embodiment 2 are preferable.

5. Verification Experiment of Sample Panel

Then, a panel is actually produced as a sample using the photomaskshaving the patterns shown in FIG. 9 and subjected to a verificationexperiment. The results are shown below. FIGS. 14( a) and 15(a) are topviews schematically showing appearances of photomasks 300, 301, 302, and303 used in this verification experiment. FIG. 14( a) shows photomasks300 and 301 for the TFT array substrate. FIG. 15( a) shows photomasks302 and 303 for the CF substrate. In this verification experiment, asubstrate in 7-inch model is subjected to an experiment for the screenjoint shot. As shown in FIGS. 14( a) and 15(a), the left side of thesubstrate is exposed in the 1st shot and the right side of the substrateis exposed in the 2nd shot. The upper line (LINE_A) is a mask parthaving an overlapping region 11 and a halftone part 12 in accordancewith the present Embodiment. The lower line (LINE_B) is a comparativemask part having neither the overlapping region 11 nor the halftone part12. In the region other than the shielding region 21, the stripe patternfor dividing the pixel into four domains, as shown in FIG. 4, isbasically formed. The masks for exposing the TFT array substrate 300 and301 each include transmissive parts S and shielding parts L which areformed in a vertical strip pattern. Each of the transmissive parts S andthe shielding parts L has a ½ width of the pixel pitch. The masks forexposing the CF substrate 302 and 303 each include transmissive parts Sand shielding parts L which are formed in a horizontal strip pattern.Each of the transmissive parts S and the shielding parts L has a ¼ widthof the pixel pitch. In the halftone part 12 of the photomasks 300 and301, the transmissive part S in the vertical direction does not have a ½width of the pixel pitch, and the halftone (graduation) is formed, inaccordance with the pattern shown in FIG. 9, i.e., by graduallydecreasing the width of the transmissive part S. In the halftone part ofthe photomasks 302 and 303, the transmissive part S in the horizontaldirection does not have a ¼ width of the pixel pitch and the halftone(graduation) is formed, in accordance with the pattern shown in FIG. 6(b), by gradually decreasing the width of the transmissive part S. Eachpixel in the panel in 7-inch model used in this verification experimenthas a length of 362.5 μm and a width of 107 μm. In the transmissive partS in the halftone part of the photomasks 300 and 301, as shown in FIGS.14( b) and 15(b), the aperture ratio is the same in every three pixels(unit of RGB), that is, within a 321 μm pitch. That is, the apertureratio of the transmissive part S is changed in every three pixels (oneunit of RGB). In the halftone part, the shielding parts S arelithographed in such a way that the width of the shielding part S isdecreased from the both sides by 1.07 μm that is the minimum grid width.If the shielding parts S are lithographed in such a manner, as a result,the aperture ratio in the shielding part S in the half tone part can bechanged by 2%. In this verification experiment, the aperture ratio inthe shielding part S in the halftone part of the photomasks 300 and 301is changed in accordance with a linear function. As a result, theaperture ratio can be changed very smoothly. In the transmissive part Sin the halftone part of the photomasks 302 and 303, the aperture ratiois the same in every pixel unit, that is, within a 362.5 μm pitch. Thatis, the aperture ratio of the transmissive part S is changed in everythree pixels (one unit of RGB). In the halftone part, the shieldingparts S are formed in such a way that the width of the shielding part Sis decreased from the both sides by 1.8215 μm that is the minimum gridwidth. If the shielding parts S are formed in such a manner, as aresult, the aperture ratio in the shielding part S in the halftone partcan be changed by 2%. In the present verification experiment, theaperture ratio in the shielding part S in the halftone part in thephotomasks 302 and 303 is changed in accordance with a linear function.As a result, the aperture ratio can be changed very smoothly.

The changing rate of the aperture ratio in the light shielding part S inthe halftone part is at most 2% or so, at present, in the pixel size ofthe 7-inch panel used in this verification experiment. The changing rateis not especially limited to 2% and may be appropriately determined.However, in order to produce the liquid crystal display devicerelatively inexpensively, the mask needs to be lithographed using arelatively common device as lithography equipment. In this case, themask is lithographed by a process with accuracy lower than that in anultra-micro machining photolithography process of a semiconductorprocess. Therefore, the minimum line width which can be lithographed isnaturally limited. This minimum line width is substantially 1 μm,generally. It is difficult to lithograph the mask with a line width insub-micro size and further produce the mask inexpensively. Therefore,the present inventors made various investigations on whether the jointline can be eliminated at a changing rate of 2% obtained when the linewidth of the mask is the minimum line width of about 1 μm, with the viewof costs on the mask in mass production of the panel. FIG. 26 shows anaperture ratio in each position of the halftone part in the photomasks300, 301, 302 and 303. In FIG. 26, the HT part shows the halftone part.

The LINE_A is a line where the halftone part in accordance with theembodiments in FIGS. 6 and 9, which the present inventors though as anoptimal pattern, is formed. The LINE_B is a line arranged in order toprove that the joint line of the photomask is observed if the photomaskhas no halftone part shown in FIG. 8. Materials used for producing theliquid crystal display panel and conditions of the production processmay be appropriately determined from those mentioned above. In thisverification experiment, the following materials and the conditions areemployed as a liquid crystal material, a pretilt angle, a cellthickness, and a proximity gap and a UV light source.

Liquid crystal material: MLC6609 (trade name, product of Merck Ltd.,Japan.), Δn=0.077, Δ∈=−3.7, Tni=80° C.

Pretilt angle: 89.0°

Cell thickness: 3.5 μm

Proximity gap: 150 μm

Light source: polarized UV of a low pressure mercury lamp The usedwavelength range is 260 nm or more.

Extinction ratio of polarized UV (polarization degree): 9:1

The prepared panel was once subjected to an annealing treatment at atemperature higher than the Tni point of the liquid crystal material for30 minutes. Then, the temperature was decreased to a normal temperature.Under this state, the panel was placed between polarizers in aCross-Nicol state and then observed on a light table. As a result, lightleakage was not observed at all, which proved that the liquid crystalmolecules were aligned almost vertically to the normal line direction ofthe substrate. Then, a rectangular wave voltage of 30 Hz was applied tothe panel, and thereby the screen during voltage application wasobserved. The panel and the polarizers were arranged in such a way thatthe UV irradiation azimuth relative to the upper and lower substrateswas the same as the absorption axis azimuths of the polarizers formed onthe respective substrates when the panel was viewed in plane, and thenthe observation was performed.

FIG. 16 shows measurement results of V (applied voltage) −T(transmittance) characteristics of the panel used in this verificationexperiment. In FIG. 16, the vertical axis shows a transmittance (%) ateach voltage relative to 100 of an intensity of transmissive light whena voltage of 7 V is applied. In this panel, the liquid crystal moleculesstarted to rise (started to be tilted) at about 2.5 V, and thereby thetransmittance started to increase. When the panel was observed at abouta voltage slightly higher than 2.5 V that is a threshold, the joint lineon the screen could be clearly observed in the region which was exposedthrough the LINE_B having no halftone part. As the voltage wasincreased, the liquid crystal molecules were further tilted and thetransmittance was increased. As a result, bright display was obtained onthe right and left sides of the joint line. At this time, the joint linewas still observed in the LINE_B region. However, it was not so clearlyobserved in comparison to the joint line which was observed within arange of the voltages slightly higher than the threshold voltage. Then,the panel was observed when a voltage of 2.84 V was applied. The voltageof 2.84 V is within the voltage range where the joint line was mostclearly observed. The voltage of 2.84 V corresponds to 96 grading valuein this panel and the transmittance at 2.84 V corresponds to about 12%if white display at 7V is defined as 255 grading value. In contrast, inthe region which was exposed through LINE_A (hereinafter, also referredto as “LINE_A region”) having a pattern which was expected to be anoptimal pattern, the joint line like that observed in the LINE_B regionwas not observed at all. It could be proven that, in the actuallyproduced panel, the joint can be completely eliminated if the photoalignment films are exposed using the photomasks having the pattern inaccordance with the present Embodiment.

The present inventors considered the reason why the joint line observedin the LINE_B region was generated. As a result, it is proven that thejoint line is observed mainly because of a difference in alignmentaccuracy of the mask between the right and left sides of the joint line,although it is also caused because of the difference in the exposureconditions between the right and left sides such as irradiation amount,polarization axis direction, proximity gap, and extinction ratio. It waspractically difficult to completely accurately position the mask for the1st shot (shot for the left region) and the mask for the 2nd shot (shotfor the right region). It can be expected that as the substrate becomeslarger, the accuracy of the practical exposure device is reduced.Further, it was proven that the actual value (range of error) in thealignment accuracy of the mask is ±2 μm to ±6 μm or so. Further, it wasproven that the joint line is observed because of the following reasons.That is, if the mask misalignment occurs on the right and left sides ofthe joint line, an area ratio of the four domains in the pixel becomesdifferent. For example, as shown in FIG. 17, the case where the mask ismisaligned to the right in the 1st shot and the mask is misaligned tothe left in the 2nd shot for the TFT array substrate and under such astate, the substrate is irradiated, is mentioned. In such a case, theoptical characteristics in the front direction are not theoreticallyinfluenced. However, if the panel is observed from an oblique direction,the four domains which differ in an area ratio (the domains L1 to L4 inthe region on the left side of the joint line and the domains R1 to R4in the region on the right side of the joint line) are averaged to beobserved. Accordingly, the optical characteristics are largely differentbetween the right and left sides of the joint line. This seems to be themain reason why the joint line is observed.

Therefore, the masks were purposely misaligned previously as shown inFIG. 17 and under such a state, the substrate was irradiated, therebyproducing a panel. Specifically, as shown in FIG. 17, the mask for the1st shot was misaligned to the right by 6 μm and the TFT substrate isirradiated. The mask for the 2nd shot was misaligned to the left by 6 μmand the TFT substrate was irradiated. In such a manner, the panel wasprepared. For simplification, the mask which was used for irradiatingthe CF substrate was not misaligned. In this case, the A shot and the Bshot in the 1st shot are shifted to the right by 6 μm. The A shot andthe B shot in the 2nd shot are shifted to the left by 6 μm.

Table 2 shows the results obtained by visually observing the panelincluding the TFT substrate which was exposed under the state the maskswere misaligned. As mentioned above, the panel was observed at 2.84 V(96 grading value) and 30 Hz. As shown in FIG. 18, the overlappingregion 11, the right region of the joint line 18, which is positioned onthe right side of the joint line 20, and the left region of the jointline 19, which is positioned on the left side of the joint line 20, wereeach observed in the upper, lower, left, right, upper left, and lowerright directions. In the right region of the joint line 18, a regionR_(A) positioned in the LINE_A region and a region R_(B) positioned inthe LINE_B region were observed. In the left region of the joint line19, a region L_(A) positioned in the LINE_A region and a region L_(B)positioned in the LINE_B region were observed. In the LINE_B region, theluminance was discontinuously observed between the right and leftregions of the joint line when the region was observed in a directionslightly tilted from the front direction, and the joint line was clearlyobserved. Particularly, when the panel was observed in the upperdirection, the region L_(B) on the left side of the joint line wasobserved more brightly than the region R_(B) on the right side of thejoint line. When the panel was observed in the lower direction, theregion R_(B) was observed more brightly than the region L_(B). As aresult, the brightness was discontinuously connected between the regionsL_(B) and R_(B), and the joint line was clearly observed. In contrast,in the LINE_A region which was exposed using the halftone pattern inaccordance with the present Embodiment, the joint line was not observed,and the screen was smoothly connected from the left to the right or fromthe right to the left of the joint line. Further, when the panel wasobserved in the upper direction, the region L_(A) was observed morebrightly than the region R_(A). When the panel was observed in the lowerdirection, the region R_(A) was observed more brightly than the regionL_(A). However, the luminance between the regions R_(A) and L_(A) wascontinuously observed and the joint line was not observed. Between theregions L_(A) and L_(B), and between the regions R_(A) and R_(B), theluminance was not different.

TABLE 2 Visual observation result (particularly how the joint line wasobserved) LINE_A The joint line was not observed. The joint line wasobserved to be smoothly connected between the right and left sides ofthe joint line. When observed in the upper direction and the upper leftdirection, the L_(A) region was observed to be brighter than the R_(A)region. When observed in the lower direction and the lower rightdirection, the R_(A) region was observed to be brighter than the L_(A)region. However, the luminance was observed to be continuously connectedbetween the L_(A) and R_(A) regions and the joint line was observed.LINE_B The luminance was observed to be discontinuously changed betweenthe right and left sides of the joint line, and the joint line wasclearly observed. When observed in the upper direction and the upperleft direction, the L_(B) region was observed to be brighter than theR_(B) region. When observed in the lower direction and the lower rightdirection, the R_(B) region was observed to be brighter than the L_(B)region. The luminance was observed to be discontinuously connectedbetween the L_(B) and R_(B) regions, and the joint line was clearlyobserved. Remarks How the joint line was observed was not differentbetween column the LA and LB regions, and between the RA and RB regions.

In the liquid crystal display device in accordance with the presentEmbodiment, even if the masks were misaligned to the opposed sidesbetween the right and left sides of the joint line when the screen jointshot process was performed, the discontinuous luminance near the jointline on the screen could be changed into the continuous luminance byexposing the substrate using the photomask having the halftone part. Asa result, the joint line could be eliminated. Thus, the presentinventors could provide a production method of a liquid crystal displaydevice and a liquid crystal display device, preferably used in thescreen joint shot for a large substrate. As mentioned above, the mainreason why the joint line is generated is the misalignment of the mask.Further, the joint line was not so caused by the difference in theexposure conditions between the right and left sides of the joint line,such as an irradiation amount, a polarization axis direction of UV,proximity gap, and extinction ratio. The present inventors verified thateven if the exposure step was performed under the state where all ofthese exposure conditions other than the misalignment of the mask weredifferent between the right and left sides of the joint line, theoccurrence frequency of the joint line resulting from these differenceswas smaller than the occurrence frequency of the joint line resultingfrom the misalignment of the mask. It was also shown that even if theexposure step was performed under the state where the all of theexposure conditions other than the misalignment of the mask weredifferent between the right and left sides of the joint line, the jointline could be completely eliminated by adopting the screen joint shotprocess in accordance with the present Embodiment, as in the case wherethe mask was misaligned.

Thus, the effects of the liquid crystal display device in accordancewith the present Embodiment were visually observed, measured, andtheoretically examined and verified. Finally, the elimination of thejoint line in the liquid crystal display device in accordance with thepresent Embodiment is shown by the data on the position and width of thedark line in the pixel. FIG. 19 is a picture showing a region L_(A)(region L_(B)) in a pixel 26 and a picture showing a region R_(A)(region R_(B)) in a pixel 27 in the panel used in the above-mentionedverification experiment. In the region L_(A) (region L_(B)), the mask ispreviously misaligned to the right and the substrate is exposed.Therefore, the dark line generated in the vertical direction is shiftedto the right. In the region R_(A) (region R_(B)), the mask is previouslymisaligned to the left and the substrate is exposed. Therefore, the darkline generated in the vertical line is shifted to the left. According tothe present verification test, the position of the dark line is definedas a position where the minimum luminance is shown in the dark line partas shown in FIG. 20, if the BM edge on the left side in the horizontaldirection (on the A1 to A2 line in FIG. 19) is defined as a startingpoint. That is, the distance from the BM edge on the left side in thehorizontal direction (in the A1 to A2 line direction in FIG. 19) to thepart where the minimum luminance is shown) is defined as the position ofthe dark line. The width of the dark line in this verificationexperiment is defined as the length between the positions where theluminance which accounts for 90% relative to the maximum luminance inthe horizontal direction (on the A1 to A2 line in FIG. 19) as shown inthe luminance cross-section curve in FIG. 20. The panel was placed undera polarization microscope including polarizers arranged in a Cross-Nicolstate and a picture of each pixel was taken. Then, image process wasprovided for each of the taken images. In such a manner, the positionand the width of the dark line were measured. The results are shown inFIG. 21. FIGS. 21( a) and 21(b) show the measurement results of theposition and width of the dark line in A1-A2 line in FIG. 19. As seen inFIG. 21( a), in the LINE_B region, the position of the dark line wassharply changed between the right and left sides of the joint line, butin the LINE_A region, the position of the dark line was smoothly changedbetween the right and left sides of the joint line. Further, the widthof the dark line was discontinuously changed near the joint line inLINE_B region, not so sharply as the position of the dark line was.However, in the LINE_A region, the width of the dark line was smoothlyand continuously changed although the width was slightly increased inthe center of the overlapping region.

Then, the substrate was exposed under the state where a proximity gapwas previously different between the right and left sides of the jointline and thus a panel was prepared in order to further verify that thejoint exposure method using the photomask in accordance with the presentEmbodiment is also effective when the width of the dark line isdiscontinuously changed between the right and left sides of the jointline. If the proximity gap is different, a dispersion degree of lightwhich transmits the photomasks is different and as a result, the widthof the dark line is different. As the proximity gap is decreased, theexposure is performed under the state where the substrate is closer tothe photomasks. Therefore, the dark line has a smaller width. Theconditions for the panel preparation other than the proximity gap werethe same as in the verification experiment for the sample panel. Usingthe same photomask as in the above-mentioned verification experiment,the panel was produced and the position and the width of the dark linewere measured. In this verification experiment, the TFT array substrateand the CF substrates were irradiated under the state where thephotomasks were not misaligned. However, the TFT array substrate wasirradiated under the following conditions: the proximity gap of 50 μm inthe shot for the region L_(A) (region L_(B)); and the proximity gap of250 μm in the shot for the region R_(A) (region R_(B)). As in FIG. 21,the measurement results of the position and width of the dark line areshown in FIGS. 28( a) and 28(b). As seen in FIG. 28( b), the width ofthe dark line was sharply changed between the right and left sides ofthe joint line, in the LINE_B region. However, in the LINE_A region, thewidth of the dark line was smoothly changed between the right and leftsides of the joint line. Further, the position of the dark line wasdiscontinuously changed near the joint line in LINE_B region, not sosharply as the width of the dark line was. However, in the LINE_Aregion, the position of the dark line was smoothly and continuouslychanged.

The reason why the joint line is observed is because the position andwidth of the dark line are discontinuously changed between the right andleft sides of the joint line. However, as in the liquid crystal displaydevice in accordance with the present Embodiment, if the overlappingexposure is performed using the photomask having an optimal half tonepattern, the position and width of the dark line can be continuouslychanged between the right and left sides of the joint line. As a result,a screen joint shot which is preferable as a production process capableof producing a large liquid crystal TV in which the joint line is notobserved even if the screen is observed in oblique directions can beprovided. Accordingly, the present invention has very large effects.

The relationship between the visual recognition of the joint line and achanging amount of the position and width of the dark line is mentionedwith reference to Tables 3 and 4. Table 3 shows the maximum changingamount (maximum difference value) of the position of the dark linebetween adjacent two pixels and results of the visual observation, inthe panel obtained in the verification experiment. Specifically, themaximum changing amount of the position of the dark line was determinedby calculating an absolute value of a difference between adjacent valuesbased on the values showing the position of the dark line shown in FIGS.21( a) and 28(a). Table 4 shows the changing amount (maximum differencevalue) of the width of the dark line between adjacent two pixels andresults of the visual observation, in the panel obtained in theverification experiment. Specifically, the maximum changing amount ofthe width of the dark line was determined by calculating an absolutevalue of a difference between adjacent values based on the valuesshowing the width of the dark line shown in FIGS. 21( b) and 28(b). Withregard to the position of the dark line, the maximum difference valuebetween values showing the position of the dark line in the LINE_Aregion in FIG. 21( a) is 1.511 μm. In this case, the joint line was notobserved at all. In the LINE_B region in FIG. 21( b), the maximumdifference value of the position of the dark line is 12.95 μm. In thiscase, the joint line was clearly observed. In the LINE_A region in FIG.28( a), the maximum difference value of the position of the dark line is1.522 μm. In this case, the joint line was not observed at all. In theLINE_B region in FIG. 28( b), the maximum difference value of theposition of the dark line is 4.348 μm. In this case, the joint line washardly observed. Then, with regard to the width of the dark line, themaximum difference value of the width of the dark line in the LINE_Aregion in FIG. 21( a) is 2.158 μm. In this case, the joint line was notobserved at all. In the LINE_B region in FIG. 21( b), the maximumdifference value of the width of the dark line is 1.727 μm. In thiscase, the joint line was not observed at all. In the LINE_A region inFIG. 28( a), the maximum difference value of the width of the dark lineis 2.826 μm. In this case, the joint line was not observed at all. Inthe LINE_B region in FIG. 28( b), the maximum difference value of thewidth of the dark line is 7.826 μm. In this case, the joint line wasobserved. These results show that in order for the joint line to becomeinvisible, that is, in order to continuously change the position andwidth of the dark line between adjacent two pixels, it is preferable thechanging amount of the position of the dark line between adjacent twopixels is less than 5 μm and the change amount of the width is 3 μm orless. Further, it is more preferable that the changing amount of theposition is 2 μm or less and the changing amount of the width is 3 μm orless.

TABLE 3 The maximum value of difference in dark line Visual positionbetween observation adjacent two pixels (μm) result FIG. 21 (a) LNE_A1.511 Joint line was not observed at all LNE_B 12.95 Joint line wasclearly observed FIG. 28 (a) LNE_A 1.522 Joint line was not observed atall LNE_B 4.348 Joint line was hardly observed

TABLE 4 The maximum value of difference in dark line width Visualbetween adjacent two observation pixels (μm ) result FIG. 21 (a) LNE_A2.158 Joint line was not observed at all LNE_B 1.727 Joint line was notobserved at all FIG. 28 (a) LNE_A 2.826 Joint line was not observed atall LNE_B 7.826 Joint line was observed

The liquid crystal display device having a configuration in which thedark lines in the vertical and horizontal directions are entirelyobserved in the pixel is mentioned above, but the liquid crystal displaydevice may have a configuration in which the dark lines are partlyshielded by a shielding body such as a BM. In such a case, the positionand width of the dark lines which are not shielded by the shielding bodyare continuously connected. If the dark lines in the vertical andhorizontal directions are completely shielded by the shielding body suchas BM in all of the pixels in the liquid crystal display device, thesame operation and effects as in the liquid crystal display device inaccordance with the present Embodiment can be exhibited as long as theposition and the width of the shielding body are continuously andsmoothly changed. If the dark lines are completely shielded by theshielding body, it is preferable that the shielding body has a widthlarger than the width of the dark line such that the dark line does notenter the display region (pixel opening).

Embodiment 2

A liquid crystal display device in accordance with Embodiment 2 of thepresent invention is mentioned below.

FIG. 22 is a schematic view showing a screen joint shot process inaccordance with the present Embodiment. As shown in FIG. 22( a), thisprocess adopts scanning exposure in which the light source 15 and thephotomask 200 are integrally moved or the substrate 16 is moved with thelight source 15 and the photomask 200 being fixed. FIG. 22( a) shows thelatter case where the substrate is moved. The substrate 16 is a TFTarray substrate. The photomask 200 is equipped with a camera for imagedetection 17 at its side. The camera scans the bus line 22 on thesubstrate 16, the BM, and the like, and in accordance with the scanning,the substrate 16 can be moved. This screen joint shot process has anadvantage that the exposure device can be downsized; costs on theexposure device are reduced; a photomask having high accuracy can beused because a small one is sufficient. The scanning exposure isexcellent in stability of the irradiation amount in the substrate plane.Therefore, a variation in characteristics of the alignment film such asan alignment azimuth and a pretilt angle can be effectively suppressed.However, the number of the portion where the screen is jointed isincreased, and therefore defects caused by the recognition of the jointline are generated, resulting in a reduction in yield.

FIG. 23 is a top view schematically showing the screen joint shotprocess in the present Embodiment when the exposure is performed whilethe light source and the photomask are integrally moved with thesubstrate being fixed. According to the present Embodiment, thephotomask 200 has an overlapping region and the overlapping region has ahalftone part 12 (gradation pattern). The moving rate of the lightsource and the photomask may be appropriately determined, and may be 6cm/sec, for example. The irradiation for the TFT array substrate 1 ismentioned, first. As shown in FIG. 23( a), the photomask 200 is moved toa specific position for which the 1st shot is provided. While acombination of the light source and the photomask (hereinafter, referredto as ahead) is moved in the +y direction, the A shot is performed.While the head is moved, the A shot is performed up to the upper end ofthe TFT array substrate 1. The photomask 200 is moved in the +xdirection by ½ of the pixel pitch in the x direction. Then, while thehead is moved in the −y direction, the B shot is performed. Then, thehead is moved in the −x direction to the position for which the 2nd shotis provided. While the head is moved in the +y direction, the A shot isperformed. While the head is moved, the A shot is performed up to theupper end of the TFT array substrate 1. The photomask 200 is moved inthe +x direction by ½ of the pixel pitch in the x direction. Then, whilethe head is moved in the −y direction, the B shot is performed. Then, aseries of this scanning exposure is repeated until completion of theexposure for the entire substrate region. Also for the CF substrate 2,the exposure is performed in the same manner, as shown in FIG. 23( b).Then, the cell is prepared in common procedures and then the liquidcrystal material is injected to complete the panel. As shown in FIG. 22(b), when a voltage not lower than a threshold is applied, thefour-domain alignment division in which the liquid crystal molecules 3 aare aligned in four azimuths can be provided. That is, if the panel isviewed in plane during voltage application, the liquid crystal molecules3 a positioned near the middle layer of the liquid crystal layer arealigned in directions at substantially 45° relative to the scanningdirections A and B when the TFT array substrate 1 is exposed and thescanning directions A and B when the CF substrate 2 is exposed.According to the present Embodiment, the order of the 1st shot and the2nd shot and the order of the A shot and the B shot are not limited tothe above-mentioned order, and it may be appropriately determined. Asshown in FIG. 24, if the scanning exposure is performed using thephotomask having neither the overlapping region nor the halftone part,the joint line attributed to the discontinuous position and width of thedark line is observed.

A way of forming the halftone in the photomask 200 in the presentEmbodiment is mentioned below. The photomask 200 in the presentEmbodiment basically has a stripe pattern for dividing each pixel intofour domains (for example, a pattern including transmissive parts S andshielding parts L each having a width of ½ or ¼ of the pixel pitch), asshown in FIG. 4. Further, the photomask 200 has a specific region as theoverlapping region near the joint line. The overlapping region near thejoint line includes the halftone part where a specific graduation isprovided for the transmissive parts S in a stripe pattern. The apertureratio in the transmissive part S in the halftone part is graduallychanged. Accordingly, the photomask having the same pattern as in thephotomask in Embodiment 1, specifically, the photomask having thepattern shown in FIG. 9, 10, or 27 may be also used in the presentEmbodiment. With regard to other advantages of the screen joint shotprocess in the present Embodiment, it is easy to control the totalirradiation amount in the overlapping exposure region (the region whichis exposed twice or more through a plurality of photomasks). If thetotal irradiation amount in the overlapping region 11 is not soincreased, specifically, the length of the transmissive part S in theoverlapping region 11 is gradually decreased, as shown in FIG. 25. As aresult, the total irradiation amount can be easily controlled. In theoverlapping region of the photomask 200 in the present Embodiment, thelength y of the transmissive part may be changed in accordance with alinear function, as mentioned in Embodiment 1, but more preferably, itis changed in accordance with a trigonometric function. The employedtrigonometric function is not especially limited. For example, afunction which satisfies the followings: at the 1st shot, the length yof the transmissive part is 100(%) when 0≦x≦Δx is satisfied and thelength y of the transmissive part satisfies the following formula (1)when Δx≦x≦45 is satisfied; at the 2nd shot, the length y of thetransmissive part is 100 (%) when 45−Δx≦x≦45 is satisfied and the lengthy of the transmissive part satisfies the following formula when0≦x≦45−Δx is satisfied; and a function that is the same as the abovefunction except that the formula (1) in the above-mentioned function isreplaced with the following formula (3) and the formula (2) is replacedwith the following formula (4), and the like, are preferable. As shownin FIG. 11, x represents a position (mm) of the overlapping region; Δxrepresents a length (mm) of a region that is not the halftone part inthe overlapping region, that is, a region where the aperture ratio is100%. The 100% of the length y of the transmissive part means that thelength y in the transmissive part is the same as the length of thetransmissive part where the aperture ratio is 100%.

$\begin{matrix}{\left\lbrack {{Equation}\mspace{14mu} 1} \right\rbrack\mspace{616mu}} & \; \\{y = {100{\cos^{4}\left( {\frac{x - {\Delta\; x}}{90 - {2\Delta\; x}}\pi} \right)}}} & (1) \\{\left\lbrack {{Equation}{\mspace{11mu}\;}2} \right\rbrack\mspace{616mu}} & \; \\{y = {100{\sin^{4}\left( {\frac{x}{90 - {2\Delta\; x}}\pi} \right)}}} & (2) \\{\left\lbrack {{Equation}{\mspace{11mu}\;}3} \right\rbrack\mspace{616mu}} & \; \\{y = {100{\cos^{2}\left( {\frac{x - {\Delta\; x}}{90 - {2\Delta\; x}}\pi} \right)}}} & (3) \\{\left\lbrack {{Equation}{\mspace{11mu}\;}4} \right\rbrack\mspace{616mu}} & \; \\{y = {100{\sin^{2}\left( {\frac{x}{90 - {2\Delta\; x}}\pi} \right)}}} & (4)\end{matrix}$

FIGS. 12 and 13 show calculation results of the change in the apertureratio from the above-mentioned formulae (1) to (4). FIG. 12( a) showsresults obtained when Δx is 0 (mm) based on the formulae (1) and (2). Inthe overlapping region, the total irradiation amount in the region whichis exposed twice in the 1st and 2nd shots can be the maximum 50%. FIG.12( b) shows results obtained when Δx is 0 (mm) based on the formulae(3) and (4). In the overlapping region, the total irradiation amount canbe the maximum100%. FIG. 13( a) shows results obtained when the Δx is11.25 (mm) based on the formulae (3) and (4), and the total irradiationamount in the overlapping region can be the maximum 150%. FIG. 13( b)shows results obtained when Δx is 22.5 (mm) based on the formulae (3)and (4). In the overlapping region, the total irradiation amount can bethe maximum 200%. Thus, according to the present Embodiment, theemployed trigonometric function formula and the Δx value can beappropriately determined, and thereby a desired total irradiation amountcan be obtained. In addition, the lengths y of the transmissive parts,that is, the aperture ratio in the transmissive part is changed inaccordance with a trigonometric function, and thereby the differentialcoefficient of change in the aperture ratio between both ends of thehalftone part can be substantially zero, and the position of the darkline can be more smoothly connected in comparison to the linearfunction. As a result, generation of defects attributed to therecognition of the joint line can be more suppressed. If the number ofthe joint part might be increased in the screen joint shot process inthe present Embodiment, the trigonometric functions shown in FIGS. 12and 13 are more preferably adopted as a function of the change in theaperture ratio of the photomask 200.

The reason why the joint line becomes invisible by controlling the totalirradiation amount is mentioned below with reference to FIG. 29. FIG. 29is a view showing regions which are exposed by scanning exposure usingthe photomasks shown in FIG. 25. Similarly to FIG. 8( b) and the like,in FIG. 29, the upper line shows a state where the exposure is performedwithout misaligning of the photomasks, and the lower line shows a statewhere the exposure is performed under the state where the photomasks aremisaligned to opposed sides. The aperture ratio in each transmissivepart is shown above and below the upper line. As shown in the lower linein FIG. 29, the total irradiation amount in each pixel is graduallychanged, and therefore the position where the dark line is formed (theposition of the arrow in FIG. 29) is also gradually changed.Accordingly, it is shown that the joint line is invisible even if thescanning exposure is performed using the photomasks shown in FIG. 25.

If the total irradiation amount in the overlapping region is notincreased, a photomask shown in FIG. 30( a) is preferably used.According to the photomask shown in FIG. 30, the alignment accuracy ofthe photomask is ±3 μm. The pattern of the photomask is designed on theassumption that a difference between the 1st shot and the 2nd shot,caused by the misalignment, is the maximum 6 μm. The upper line in FIG.30( b) shows that the substrate is exposed in the 1st and 2nd shotswithout misalignment of the photomasks. The middle line in FIG. 30( b)shows that the substrate is exposed under the state where the photomaskis shifted to the right by about 6 μm in 1st shot. The lower line inFIG. 30( b) shows that the substrate is exposed under the state wherethe photomask is shifted to the left by about 6 μm in the 1st shot. Thisphotomask has a halftone part shown in FIG. 30, in the overlappingregion near the joint line. In the halftone part, as shown in FIG. 30(a), transmissive parts S having a step shape are formed and thetransmissive parts S are arranged in descending order toward the end ofthe halftone part. More specifically, each of the transmissive partspositioned near the center of the halftone part has a step part having alength substantially half the length of the transmissive part. Thetransmissive parts S in the halftone part include a transmissive part Shaving a shape which is axial symmetry to the centerline which bisectsthe width of the transmissive part-arranged region. A transmissive partS which is divided from the center of the transmissive part-arrangedregion to both sides is arranged on the end side of the photomask in thehalftone part. In the transmissive parts S on the end side of thephotomask in the halftone part, the length of the transmissive part Sgradually becomes shorter toward the end of the photomask. In thetransmissive parts S on the side opposed to the end of the photomask inthe halftone part, the length at the both ends of the transmissive partS gradually becomes longer toward the side opposed to the end of thephotomask. Each transmissive part S which is formed by being dividedfrom the center of the transmissive part-arranged region to both sideshas a shape which is axial symmetry to the center line which bisects thewidth of the transmissive part S itself. More specifically, a shapeformed by a plurality of quadrangles is preferable as a shape of theentire transmissive part having a step shape. Among these, as shown inFIG. 30( a), a shape formed by a plurality of quadrangles in a pyramidpattern is more preferable. The aperture ratio in the halftone part ofthe photomask shown in FIG. 30 is changed in accordance with thetrigonometric function shown in FIG. 12( b). Further, the transmissivepart is also formed between the transmissive parts S shown in FIG. 30.The aperture ratio is changed at a ratio as small as possible andthereby continuously changed. That is, the aperture ratio in thetransmissive part S in the halftone part is smoothly changed inaccordance with a trigonometric function such that the total apertureratio in the transmissive part S in the overlapping region is 100%. Thesize of each transmissive part S in the photomasks shown in FIG. 30 isas shown in FIG. 31. In FIG. 31, the grid pitch is 6 μm. Due to use ofsuch a photomask, as in the case where the photomask shown in FIG. 9,10, 25, or 27 is used, the position of the dark line can be continuouslychanged between the right and left sides of the joint line. Further, thetotal irradiation amount in the overlapping region can be effectivelysuppressed. More specifically, the total irradiation amount in theoverlapping region is 100% if the photomask is not misaligned as shownin the upper line in FIG. 30( b). In the case where the photomask ismisaligned, as shown in the middle and lower lines in FIG. 30( b), ifthe mask is misaligned by a distance smaller than the width of the steppart formed on the both sides of the transmissive part S (the photomaskin FIG. 30 is misaligned by 6 μm or less), a shift from 100% of thetotal irradiation amount can be suppressed to 50 to 150% which is arelatively small sift in all of the pixels positioned in the overlappingregion.

Using this photomask, the same test as the evaluation test in Embodiment1 was performed. The joint line was not observed in the front directionand oblique directions (in the entire azimuth). In the entire gradingvalue of black, white and intermediate scales, the joint line was notobserved.

In the present invention, as the difference between 100% and the totalirradiation amount in the region which is exposed twice or more throughdifferent photomasks becomes larger, the asymmetry of a pretilt anglebecomes remarkable, and the overlapping region is visible as a line.Further, if the exposure step is performed by scanning exposure as inthe present Embodiment, the scanning direction on the TFT arraysubstrate and the scanning direction on the CF substrate aresubstantially perpendicular to each other generally, when the substratesare attached. Therefore, a difference in this asymmetry of the pretiltangle is very small. Accordingly, the photomasks shown in FIG. 30 whichcan suppress the difference between 100% and the total irradiationamount in the overlapping region to be a relatively small value can beparticularly effectively used when the exposure step is performed byscanning exposure as in the present Embodiment.

The total irradiation amount when the scanning exposure is performedusing the respective photomasks in Embodiments 1 and 2 is mentionedbelow. If the scanning exposure is performed using the photomasks shownin FIGS. 9 and 10, the total irradiation amount in the overlappingregion is 100% or 200% regardless of whether or not the photomasks aremisaligned. Particularly in the overlapping exposure region, thealignment film is exposed at the maximum 200% that is twice as large asa general irradiation amount. If the scanning exposure is performedusing the photomasks shown in FIG. 27, in the overlapping region,particularly in the region where the length of the transmissive part isgradually decreased, the total irradiation amount can be 150% or less.

The patterns of the photomasks used for the 1st and 2nd shots, shown inFIG. 30, have the following relationship: in each transmissivepart-arranged region in the halftone part, the shape of the transmissivepart and that of the shielding part do not have an inverted relationshipbut an opposite relationship relative to the center line of thetransmissive part-arranged region in the scanning direction. However,the photomasks for the 1st and 2nd shots in accordance with the presentEmbodiment may be in the following relationship as shown in FIG. 32( a):in each transmissive part-arranged region in the halftone part, thetransmissive part and the shielding part are opposed; but the shape ofthe transmissive part and the shape of the shielding part are notsymmetry to the center line in the transmissive part-arranged region inthe scanning direction. Also using such photomasks, as shown in FIG. 32(b), similarly to the photomasks in FIG. 30, the total irradiation amountin the overlapping region can be within 50 to 150%, and the joint linecan become invisible. The pattern shown in FIG. 32 also can be appliedfor a photomask used in the simultaneous scanning as in Embodiment 1.That is, if the photomask shown in FIG. 32 is used in the simultaneousexposure, as shown in FIG. 33, as each of the photomasks used in the 1stand 2nd shots, a photomask in which slits are formed in a step pattern,in a plurality of columns corresponding to the number of arrays of theexposed pixel, may be used. In FIG. 32, the transmissive partscorresponding to the pixels indifferent columns are partitioned with asolid line, but practically, the transmissive parts are connected in thecolumn direction, generally.

The present application claims priority under the Paris Convention andthe domestic law in the country to be entered into national phase onPatent Application No. 2006-17755 filed in Japan on Jan. 26, 2006, theentire contents of which are hereby incorporated by reference.

The terms “or more” and “or less” in the present description mean thatthe described value is included.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a cross-sectional view schematically showing the screen jointshot process in accordance with Embodiment 1.

FIG. 2( a) is a cross-sectional view schematically showing aconfiguration of the liquid crystal display device in accordance withEmbodiment 1.

The left figure in FIG. 2( b) is a planar view schematically showing, inone pixel, a direction of the UV irradiation treatment which is providedfor the vertical alignment films each formed on the surface of the TFTarray substrate that is the first substrate and on the surface of the CFsubstrate that is the second substrate, and an alignment azimuth ofliquid crystal molecules near the middle layer in the liquid crystallayer when a voltage not lower than a threshold is applied.

The right figure in FIG. 2( b) is a planar view schematically showing apolarization axis direction P of the upper polarizer 24 a and apolarization axis direction Q of the lower polarizer 24 b.

FIG. 3( a) is a planar view schematically showing, in one pixel, adirection of the UV irradiation treatment which is provided for thesurface of the vertical alignment film formed on the surface of the TFTarray substrate that is the first substrate.

FIG. 3( b) is a planar view schematically showing, in one pixel, adirection of the UV irradiation treatment which is provided for thesurface of the vertical alignment film formed on the surface of the CFsubstrate that is the second substrate.

FIG. 4 is a schematic view explaining the UV irradiation direction forthe four-domain alignment division.

FIG. 4( a) is a planer view schematically showing a direction of the UVirradiation treatment for the TFT array substrate.

FIG. 4( b) is a planar view schematically showing a direction of the UVirradiation treatment for the CF substrate.

FIG. 4( c) is a perspective view schematically showing an embodiment ofthe UV irradiation treatment for the TFT array substrate or the CFsubstrate.

FIG. 4( d) is a cross-sectional view schematically showing an embodimentof the UV irradiation treatment for the TFT array substrate or the CFsubstrate.

FIG. 5 is a planar view schematically showing the screen joint shotmethod in Embodiment 1.

FIG. 6 is a top view schematically showing the screen joint shot methodin Embodiment 1 in which the measures for eliminating the joint line aretaken and an enlarged schematic view showing the mask pattern in theoverlapping region.

FIG. 6( a) is a top view schematically showing the embodiments of the1st and 2nd shots for the TFT array substrate and an enlarged schematicview showing the photomask pattern in the overlapping region of thephotomasks used for exposing the TFT array substrate.

FIG. 6( b) is a top view schematically showing the embodiments of the1st and 2nd shots for the CF substrate 2 and an enlarged schematic viewshowing the photomask pattern in the overlapping region of thephotomasks used for exposing the CF substrate.

FIG. 7 is a top view schematically showing the screen joint shot methodin the comparative Embodiment in which the measures for eliminating thejoint line are not taken.

FIG. 7( a) is a top view schematically showing embodiments of the 1stand 2nd shots for the TFT array substrate.

FIG. 7( b) is a top view schematically showing embodiments of the 1stand 2nd shots for the CF substrate.

FIG. 8 is a schematic view explaining the photomask used in the screenjoint shot process in the comparative embodiment in which the measuresfor eliminating the joint line are not taken.

FIG. 8( a) is a planar view schematically showing the pattern andarrangement of the photomasks.

FIG. 8( b) is a schematic view showing a region which is exposed usingthe photomasks shown in FIG. 8( a).

FIG. 9 is a schematic view explaining the photomask used in the screenjoint shot process in accordance with Embodiment 1 in which the measuresfor eliminating the joint line are taken.

FIG. 9( a) is a planar view schematically showing the pattern andarrangement of the photomasks in the overlapping region.

FIG. 9( b) is a schematic view showing the region which is exposed usingthe photomasks shown in FIG. 9( a).

FIG. 10 is a schematic view showing another photomask used in the screenjoint shot process in Embodiment 1 in which the measures for eliminatingthe joint line are taken.

FIG. 10( a) is a planar view schematically showing the pattern andarrangement of the photomasks in the overlapping region.

FIG. 10( b) is a schematic view showing the region which is exposedusing the photomasks shown in FIG. 10( a).

FIG. 11 is a schematic view explaining a parameter in the overlappingregion of the photomasks in Embodiment 1 used in the screen joint shotprocess.

FIG. 12 is a graph showing a change in aperture ratio in thetransmissive part in the overlapping region of the photomask used in thescreen joint shot process in accordance with Embodiment 2.

FIG. 12( a) is a graph showing a trigonometric function and the totalirradiation amount is the maximum 50%.

FIG. 12( b) is a graph showing a trigonomertic function and the totalirradiation amount is the maximum 100%.

FIG. 13 is another graph showing a change in aperture ratio in thetransmissive part in the overlapping region of the photomask used in thescreen joint shot process in accordance with Embodiment 2.

FIG. 13( a) is a graph showing a trigonometric function and the totalirradiation amount is the maximum 150%.

FIG. 13( b) is a graph showing a trigonometric function and the totalirradiation amount is the maximum 200%.

FIG. 14( a) is a top view schematically showing the photomasks for theTFT array substrate, used in the joint line-verified experiment thescreen joint shot process, in accordance with Embodiment 1.

FIG. 14( b) is a schematic view showing a unit of three pixels (one unitof RGB).

FIG. 15( a) is a top view schematically showing the photomasks for theCF substrate, used the joint line-verified experiment, in accordancewith Embodiment 1.

FIG. 15( b) is a schematic view showing a unit of three pixels (one unitof RGB).

FIG. 16 is a graph showing applied voltage-transmittance characteristicsin the panel used for the joint line-verified experiment.

FIG. 17 is a planar view schematically explaining one pixel in the panelincluding the substrate which is exposed under the state where thepatterns of the photomasks are previously misaligned.

FIG. 18 is a planar view schematically explaining each exposure regionand the observation direction in the joint line-verified experiment inthe panel produced as a sample for the joint line-verified experiment.

FIG. 19 are pictures of pixels, which are a picture showing a rightregion and a picture showing a left region of the joint line in thepanel including the substrate which is exposed under the state where thepatterns of the photomasks are previously misaligned.

FIG. 20 is a view showing luminance characteristics (luminancecross-section curve) for explaining the position and width of the darkline in the panel including the substrate which is exposed under thestate where the patterns of the photomasks are previously misaligned, inthe joint line-verified experiment.

FIG. 21 is a graph showing analysis results of the position and width ofthe dark line in the panel including the substrate which is exposedunder the state where the patterns of the photomasks are previouslymisaligned.

FIG. 21( a) shows the position of the dark line in the overlappingregion.

FIG. 21( b) shows the width of the dark line in the overlapping region.

FIG. 22 is a schematic view showing an embodiment of the screen jointshot process in accordance with Embodiment 2.

FIG. 22( a) is a perspective view schematically showing a scanningexposure device and a planar view schematically showing a configurationof a TFT array substrate.

FIG. 22( b) is a planar view schematically showing, in one pixel, adirection of the UV irradiation treatment which is provided for thevertical alignment films each formed on the surface of the TFT arraysubstrate that is the first substrate and on the surface of the CFsubstrate that is the second substrate, and an alignment azimuth ofliquid crystal molecules near the middle layer in the liquid crystallayer when a voltage not lower than a threshold is applied.

FIG. 23 is a top view schematically showing the screen joint shot methodin Embodiment 2 in which the measures for eliminating the joint line aretaken.

FIG. 23( a) is a top view schematically showing the embodiments of the1st and 2nd shots for the TFT array substrate.

FIG. 23( b) is a top view schematically showing embodiments of the 1stand 2nd shots for the CF substrate.

FIG. 24 is a top view schematically showing the screen joint shot methodin the comparative Embodiment in which the measures for eliminating thejoint line are not taken.

FIG. 24( a) is a top view schematically showing the embodiments of the1st and 2nd shots for the TFT array substrate.

FIG. 24( b) is a top view schematically showing the embodiments of the1st and 2nd shots for the CF substrate.

FIG. 25 is a planar view schematically showing the patterns of thephotomasks used in the screen joint shot process in accordance withEmbodiment 2 in which the measures for eliminating the joint line aretaken.

FIG. 26 is a diagram showing an aperture ratio of the transmissive partin each position in the overlapping region of the photomasks for thejoint line-verified experiment.

FIG. 27 is a schematic view showing another photomask used in the screenjoint shot process in accordance with Embodiment 1 in which the measuresfor eliminating the joint line are taken.

FIG. 27( a) is a planar view schematically showing the pattern andarrangement of the photomasks in the overlapping region.

FIG. 27( b) is a schematic view showing the region which is exposedusing the photomasks shown in FIG. 27( a).

FIG. 28 is a graph showing analysis results of the position and width ofthe dark line of the panel including the substrate which is exposedunder the state where the proximity gap of the photomasks is previouslydifferent, in the joint line-verified experiment.

FIG. 28( a) shows the position of the dark line in the overlappingregion.

FIG. 28( b) shows the width of the dark line in the overlapping region.

FIG. 29 is a schematic view showing a region which is provided with thescanning exposure using the photomasks shown in FIG. 25.

FIG. 30 is a schematic view showing the photomasks used in the screenjoint shot process in accordance with Embodiment 2 in which the measuresfor eliminating the joint line are taken.

FIG. 30( a) is a planar view schematically showing the pattern andarrangement of the photomasks in the overlapping region.

FIG. 30( b) is a schematic view showing the region which is exposedusing the photomasks shown in FIG. 30( a).

FIG. 31 is a planar view schematically showing the transmissive partsand explaining the size of each transmissive part in the overlappingregion of the photomasks in FIG. 30.

FIG. 31( a) shows each transmissive part in the overlapping region ofthe photomask for the TFT array substrate. FIG. 31( b) shows eachtransmissive part in the overlapping region of the photomask for the CFsubstrate.

FIG. 32 is a schematic view showing another photomask used in the screenjoint shot process in accordance with Embodiment 2 in which the measuresfor eliminating the joint line are taken.

FIG. 32( a) is a planar view schematically showing the pattern andarrangement of the photomasks in the overlapping region.

FIG. 32( b) is a schematic view showing the region which is exposedusing the photomasks shown in FIG. 32( a).

FIG. 33 is a planar view schematically showing another photomasks usedin the screen joint shot process in accordance with Embodiment 2 inwhich the measures for eliminating the joint line are taken.

FIG. 33( a) shows the pattern in the overlapping region of thephotomasks for the TFT array substrate.

FIG. 33( b) shows the pattern in the overlapping region of thephotomasks for the CF substrate.

EXPLANATION OF NUMERALS AND SYMBOLS

-   1: The first substrate (TFT array substrate)-   2: The second substrate (CF substrate)-   3: Liquid crystal layer-   3 a: Liquid crystal molecule-   4, 4 a, 4 b: Transparent electrode-   5: Alignment film-   5 a, 5 b: Vertical alignment film-   6: Pixel-   7 a, 7 b: Horizontal alignment film-   8: Proximity gap-   9: Polarized UV-   10: Pretilt angle-   11: Overlapping region-   12: Halftone part-   13: Large substrate-   14: region exposed in one shot-   15: Light source-   16: Substrate-   17: Camera for image detection-   18: Right region of joint line-   19: Left region of joint line-   20: Joint line-   21: Shielding region-   22: Bus line-   23: TFT-   24: Polarizer-   24 a: Upper polarizer-   24 b: Lower polarizer-   25: Retarder-   26: Pixel in region L_(A) (region L_(B))-   27: Pixel in region R_(A) (region R_(B))-   101: Liquid crystal display device-   200, 200 a, 200 b, 300, 301, 302, 303: Photomask-   P: Polarization axis direction of upper polarizer-   Q: Polarization axis direction of lower polarizer-   S: Transmissive part-   L: Shielding part-   Px: Pixel pitch in x direction-   Py: Pixel pitch in y direction-   y: Length of transmissive part-   L1, L2, L3, L4, R1, R2, R3, R4: Domain-   L_(A), R_(B), L_(B), R_(B): Region

1. A production method of a liquid crystal display device, the liquidcrystal display device comprising: a pair of opposed substrates; aliquid crystal layer formed between the pair of opposed substrates; andan alignment film arranged on a liquid crystal layer side surface of atleast one of the pair of opposed substrates, and the liquid crystaldisplay device having two or more regions which differ in alignmentazimuth, wherein the production method comprises an exposure step ofexposing the alignment film in such a way that a substrate plane isdivided into two or more exposure regions through a photomask in eachexposure region, and in the exposure step, exposure is performed in sucha way that adjacent two exposure regions have an overlapping exposureregion where the adjacent two exposure regions partly overlap with eachother, and the photomask has a halftone part corresponding to theoverlapping exposure region.
 2. The production method of the liquidcrystal display device according to claim 1, wherein in the exposurestep, UV is made incident to a normal line of the substrate plane froman oblique direction.
 3. The production method of the liquid crystaldisplay device according to claim 2, wherein the UV is polarized UV. 4.The production method of the liquid crystal display device according toclaim 1, wherein the photomask has a repeated pattern consisting of atransmissive part and a shielding part.
 5. The production method of theliquid crystal display device according to claim 1, wherein the halftonepart includes transmissive parts with various aperture ratios, and thetransmissive parts are arranged in descending order of the apertureratios toward an end of the photomask.
 6. The production method of theliquid crystal display device according to claim 5, wherein in thehalftone part, a change in the aperture ratios is expressed as a linearfunction.
 7. The production method of the liquid crystal display deviceaccording to claim 5, wherein in the halftone part, a change in theaperture ratios is expressed as a trigonometric function.
 8. Theproduction method of the liquid crystal display device according toclaim 5, wherein in the halftone part, the transmissive parts havevarious widths, and the transmissive parts are arranged in descendingorder of the widths toward an end of the photomask.
 9. The productionmethod of the liquid crystal display device according to claim 8,wherein in the photomask, a distance between center positions of twoadjacent transmissive parts is uniform.
 10. The production method of theliquid crystal display device according to claim 8, wherein in thehalftone part, the transmissive parts include a transmissive part whichis divided from the center of a transmissive part-arranged region toboth sides.
 11. The production method of the liquid crystal displaydevice according to claim 5, wherein in the halftone part, thetransmissive parts include a transmissive part having a shape which isaxial symmetry to a center line which bisects a width of a transmissivepart-arranged region.